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 thermo- plastic 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”.


Miro Duhovic

Kompetenzfeldleiter Prozesssimulation

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

Room: 58/268
Economic Sectors Applications (Examples)
Aeronautics Casings, stringers and frames
Automotive Chassis and body panels
Engineering Hybrid support structures
Sports & Recreation Bicycle seats
Energy Rotor blades

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

  • Which characterization experiments are necessary for performing thermoforming simulations of CFRTP sheets and tailored blanks?
  • Which simulation methohdologies can be used to simulate the compression molding of short and ong fiber reinforced polymer composites?
  • Which characterization experimens are necessary to determine the permeability of a reinforcement textile in all three spatial directions allowing LCM filling simulations of complex 3D parts?

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