Simulation of composite processes

Purpose

At RISE, material models and simulation methods are developed to support process simulation of complex products.

Simulation of manufacturing processes is performed to predict the component's mechanical properties and predict the product's shape, which is used for tool compensation before the product is manufactured. Virtual manufacturing minimizes the need for full-scale tests, process tuning at start-up and costly changes in the process concept.

Method

Different numerical or analytical methods are used depending on which manufacturing process is to be simulated. In forming simulation of pre-impregnated continuous fiber (prepreg), commercial finite element (FE) programs are used where material models connected to the program are internally developed at RISE. Both FE and CFD (Computational Fluid Dynamics) based programs are used for forming discontinuous fiber (SMC). Fiber winding, which is a common process today for manufacturing pipes, isolators and pressure vessels, is simulated with an internally developed program (WetWind) or with commercial machine simulation programs. Injection processes such as RTM (Resin Transfer Molding) are simulated with commercial products.

Test period for material models that include temperature dependent properties, degree of cure for thermosets and crystallinity for high performance thermoplastics are available upon request.

Deliveries

As a result from process simulation, the product's mechanical properties, shape and dimension are obtained, which can be used for further tool compensation. The calculated mechanical properties of the product can be used in subsequent functional analysis to increase the accuracy. Tests of material models are provided upon request.