David Colin, M.Sc.

Research Group Leader

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

The high potential in lightweight design of composite parts is challenged by the need for automation of the manufacturing processes, the reduction of cycle times and process costs. Modeling the manufacturing process is an effective and flexible approach to understand and optimize the process long before the first prototype is built and to transfer the process information in the structural analysis of the part. Our research is based on an integral simulation platform (see figure). This platform follows "design-to-fiber" and "design-to-process" approaches and allows a customized combination of individual simulation steps (e.g. draping simulation and structural analysis) including software-neutral data exchange. The composite part is studied beginning with its manufacturing: direct preforming (braiding, AFP) or sequential preforming (draping) followed by filling simulation up to compaction, curing and consolidation simulation in close interaction with the processing groups. Material modeling, as a basis for process simulation and structural analysis, is focused on modeling thermoset and thermoplastic composites from micro- to meso- and macroscopic scales under static and dynamic loading and the modeling of bonded or mechanical joints.

The research in process simulation and structural analysis is accompanied by development of material characterization techniques (together with the testing group), the validation of the simulation approach on generic structures and its application on a part level.

Forming and Flow Process Simulation

Focuses on preforming processes such as braiding, draping and automated fibre placement as well as the simulation of the filling process of fibers, textiles and full scale parts.

Compaction, Curing and Consolidation Simulation

Focuses on the thermal, mechanical as well as flow- and compaction-related phenomena and their impact on deviations in terms of geometry - process induced deformations (PID) - and the materials architecture such as void content.

Material Modeling and Structural Analysis

Focuses on the analysis of fiber-reinforced plastics as well as mechanical and bonded joints at different length scales.