Virtual Process Chain

Our Virtual Process Chain seamlessly connects the crucial steps product design, manufacturing validation, and engineering for the virtual product development with plastics, fiber-reinforced composites, and hybrids.

It starts with the definition of a concept and results in an optimized part or assembly ready to be manufactured. This is achieved through the integration of process and warpage simulation into the digital product development cycle.

Through process simulation, the manufacturability, as well as a suitable processing strategy can be determined purely virtually. Moreover, manufacturing effects, such as the influence of the manufacturing process on the fiber orientation or fiber volume content are predicted.

The virtually predicted manufacturing effects are retained along the virtual process chain and considered in downstream simulation steps. Based on this, the part’s behavior in terms of dimensional stability and structural performance is predicted more accurately in warpage and structural analyses, respectively.

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Design & Optimization

The smart application of plastics, fiber-reinforced composites, and hybrids requires a material-specific and tailored design, to fully exploit their lightweight potential. SIMUTENCE supports the design, optimization, and development of individual lightweight structures.

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Process Simulation

The simulation of manufacturing processes is a powerful tool, which enables the virtual manufacturing validation for a specific design without any real-world manufacturing piloting or demonstrator manufacturing. Moreover, manufacturing effects, such as the resulting fiber structure, is predicted. This information can be used in downstream simulation approaches, such as warpage and spring-in analysis, to improve their prediction accuracy, respectively.

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Warpage Simulation

Manufacturing of fiber-reinforced composites and hybrids is often accompanied by process-induced deformations (PIDs), such as spring-in or warpage. Through thermomechanical analyses of the part cooling and solidification, these dimensional instabilities, as well as residual stresses, become predictable.

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Structural Simulation

The final part needs to fulfill the load requirements. These can be virtually assured by structural analyses. The structural behavior of fiber-reinforced composites, however, is distinctively influenced by manufacturing effects, which can be predicted and considered through our Virtual Process Chain.

The functional Virtual Process Chain of SIMUTENCE is based on data transfer between the simulation steps through mapping procedures. Based on this, e.g. fiber orientation or any other state variable predicted by process simulation is transferred to warpage and structural analyses. We conduct the mapping step with our mapping and homogenization product SimuChain.

SimuChain enables the export of relevant state variables from simulation results to a neutral exchange format. Currently, the export of SimuDrape, SimuFill, and Moldflow results is supported. Subsequently, the results are mapped onto the target mesh using the MpCCI Mapper, which is developed by Fraunhofer SCAI and supplied by the scapos AG. Finally, the results are imported into ABAQUS and the material cards are created through SimuChain.

As an official reseller of MpCCI Mapper, we deliver both components as a single solution. Upon request, we implement further interfaces for the im- and export, as well as material card generators for ABAQUS models with and without subroutines.

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