Simulation

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.