Process Simulation

Today, process simulation plays a crucial role in composite manufacturing science. It helps us understand, refine, and optimize the processes we use to make composite parts. At IVW, process simulation is focused on four key topics: processing of thermoplastic sheet materials, liquid composite molding, welding of thermoplastic composites by induction, and the processing of bulk molding and structural molding compound materials.

Process simulation begins with material characterization, a procedure of defining and measuring the material’s behavior, usually deformation or flow as well as thermal behavior, experienced under the specific conditions during manufacturing. In most cases temperature, strainrate, pressure and time are the key parameters. The experiments provide the source of input and form of verification required for computer simulations which can then be performed in place of physical experiments using mathematical and engineering software, essentially allowing what engineering software providers have termed “virtual manufacturing”.

Economic Sectors Applications (Examples)
Aeronautics & Space Casings, stringers and frames
Automotive Chassis and body panels
Engineering Hybrid support structures
Sports & Recreation Bicycle seats
Energy Rotor blades

Dr.

Miro Duhovic

Kompetenzfeldleiter Prozesssimulation

Spezielle Expertise: Finite-Elemente-basierte Multiphysik-Simulation komplexer Verbundwerkstoff-Fertigungsprozesse, Material- und Prozesscharakterisierung, Entwicklung von Verbundwerkstoffmodellen

Room: 58/268

Special Expertise

  • Characterization and finite-element based multi-physics simulation of highly complex composites manufacturing processes

Typical Materials

  • GFRP
  • CFRP
  • Continuously reinforced systems

Materials and Questions

Typical Questions

  • How can the thermoforming of tailored CFRTP laminates including their springback behavior be simulated?
  • Which characterization and simulation methodologies can be used to investigate the injection/compression molding of short and long fiber reinforced polymer composites?
  • How can the hydrodynamics of resin transfer from a saturated textile into a dry reinforcement be simulated in 3D?

Projects in this field

Publications from the IVW papers in this field of competence

  • Weber, T.

    Herstellprozesssimulation zur Vorhersage der Faltenbildung in der Prepreg-Autoklav-Fertigung

  • Schöpfer, J.

    Spritzgussbauteile aus kurzfaserverstärkten Kunstsoffen: Methoden der Charakterisierung und Modellierung zur nichtlinearen Simulation von statischen und crashrelevanten Lastfällen

  • Louis M.

    Zur Simulation der Prozesskette von Harzinjektionsverfahren

  • Huber, U.

    Zur methodischen Anwendung der Simulation der Harzinjektionsverfahren

    External Publications "Process Simulation"

    An experimental characterization of wrinkling generated during prepreg autoclave manufacturing using caul plate

    https://journals.sagepub.com/doi/10.1177/0021998319846556

    Advanced process simulation of compression molded carbon fiber sheet molding compound (C-SMC) parts in automotive series applications

    https://doi.org/10.1016/j.compositesa.2022.106924

    Material Characterization and Compression Molding Simulation of CF-SMC Materials in a Press Rheometry Test

    https://www.scientific.net/KEM.809.467

     

    A combined experimental–numerical approach for permeability characterization of engineering textiles

    https://onlinelibrary.wiley.com/doi/10.1002/pc.26064

     

     

    Influence of polymer matrix on the induction heating behavior of CFRPC laminates

    https://www.sciencedirect.com/science/article/pii/S1359836821009276?via%253D