Forming and Flow Process Simulation

David Colin, M.Sc.

Research Group Leader

Tel. Büro: +49 (89) 289 - 10315
Mobile +49 (162) 2506850

The Preforming and Flow Process Simulation research team focuses on the braiding, draping and automated fiber placement processes as well as the simulation of the filling process for fibers, textiles and full scale parts. Indeed, simulation tools must be developed as there have been no industrial standards established to date. The relation between material properties and manufacturing parameters is of particular importance. In the future, there is enormous potential in understanding and modeling manufacturing processes.

Draping simulation

In the field of draping and forming simulation, the LCC focuses on the development of methodologies to model, via a finite-element approach, several different types of composite reinforcements (dry, thermoset and thermoplastic pre-impregnated). Numerical inputs are defined via extensive material characterizations. The validation of the simulation models are performed by comparisons of both the experimental and the simulation results of the use-cases.

Braiding simulation

Investigations of the braiding process are conducted via finite-element-simulations. The analyses focus on the relationship between the different process parameters and their influence on the braided structure. Testing is used to determine the key process parameters. Simulation models are validated by experiments performed with the braiding machine available at the LCC.

Simulation of the AFP process

A simulation model of the Automated Fiber Placement (AFP) process is developed to understand the relationship between the thermal and mechanical process parameters. In addition to analytical modeling, thermo-mechanically coupled simulations are applied. The validation of the simulation models is achieved with the AFP equipment available at the LCC. The simulation models are being used to optimize the AFP layup and reduce iteration cycles for testing.

Simulation of the RTM process

The simulation of the Resin Transfer Molding (RTM) is investigated with main focus on material characterization and model validation. A simulation approach has been developed for permeability prediction, where images from scanned fabrics are analyzed. A unit-cell fabric model is derived from the results, and then a fluid simulation is performed to obtain permeability. So, process parameters like injection pressure, fill time or flow front progression can be predicted.