Verstehen statt Trial-and-Error: Prozesssimulation zum Nutzen der Industrie
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1 Prof. Dr. Vasily Ploshikhin Airbus endowed chair / University of Bremen Verstehen statt Trial-and-Error: Prozesssimulation zum Nutzen der Industrie Bremen,
2 Organization research team Staff: - 2 head / administration - 6 scientists (+5) - 4 working students (+3) WG Manufacturing and Properties of Composites (MPC) Jan-Patrick Jürgens group leader CFRP micromechanics HEAD Prof. Dr. Ing. Vasily Ploshikhin ADMINISTRATION WG Additive Layer Manufacturing (ALM) Karin Schütte administration assistant Nils Keller group leader PDB and powder deposition methods Reza Malek Markus Rullich Oliver Illies Melissa Matzen NN ( ) Hongxiao Xu Michael Kühl * Christian Kober Stefanie Jeske NN ( ) scientist defects scientist CNTs scientist thermal conductivity working student Airbus moisture effects working student distortion scientist powder and wire deposition master student Airbus fire safety simulations working Student ALM working student ALM working student ALM 2 * Candidate for research staff, employment during the 1st quarter of 2012 in discussion
3 Research Research directions Composites: Micro- and Nano- Engineering Micro-mechanics of curing - residual stress - micro-cracking Carbon nano-tubes reinforcement - electrical properties - mechanical properties Thermal and electrical conductivity Metals: ALM and Fire Safety Moisture effects and formation of pores ALM process simulation - residual stress & distortion - thermal process control Fire safety simulations 3
4 Manufacturing and Properties of Composites Micromechanics of curing process time 4 Numerical predictions: - stress and distortion - process induced micro-cracks
5 Manufacturing and Properties of Composites Carbon nanotubes reinforced polymers Prediction of mechanical and electrical properties of carbon nanotube reinforced polymers (CNRP) Zoom of the coating used for percolation evaluation 2 percolating clusters 5 RVE / FE mesh
6 Manufacturing and Properties of Composites Thermal and electrical conductivity of CFRP Tet-mesh used in 3D simulation Quad mesh 2D simulation 6
7 Manufacturing and Properties of Composites Formation and effects of pores voids free microstructure voids (1%) prone to damage initiation normal stress yy Cross-section of 3D simulation 7
8 Additive Layer Manufacturing ALM / selective laser melting (powder) Temperature distribution t = 1000 sec t = 2250 sec (end of process) Stress distribution 8
9 Additive Layer Manufacturing ALM / Arc thermal spraying (wire) Heute: In Arbeit: Werkzeuge mit konturnahen Temperierung Quelle: Premium airotech Quelle: EADS IW / 9 /
10 Additive Layer Manufacturing ALM / Arc thermal spraying (wire) Tool outer surface Tool inner surface Tempering channels frame Temperierkanäle (Sicht von unten) Konturnahe Temperierkanal (Querschnitt) / 10 / Patent application: submitted on
11 Additive Layer Manufacturing ALM / Plate diffusion brazing (sheets) Patent application: submitted on D plates Plate diffusion brazing (PDB) 11 Complex 3D structure
12 Fire Safety Simulations Fire Safety Simulations 600 Reconstructed cooling curve Temperature AA7475 2mm thick exp simulation 100 temperature distribution (experiment) Heat transfer coefficient α reconstructed for different materials/thickness 12 α [W/mmK] 3,50E-005 3,00E-005 2,50E-005 2,00E-005 1,50E-005 1,00E-005 5,00E-006 0,00E Time [s] aa7475 4mm aa7475 2mm aa2024 4mm
![reconstructed for different materials/thickness 12 α [W/mmK] 3,50E-005 3,00E-005 2,50E-005 2,00E-005](/docs-images/43/6001246/images/page_12.jpg "1,50E-005 1,00E-005 5,00E-006 0,00E+000 12 0 0 500 1000 1500 0 100 200 300 400 500 Time [s] aa7475 4mm")
13 Cooperation Integration of other research partners University of Bremen Fiber Institute Institute for Materials Technology Prof. Frauenheim atomistic simulations Carbon nanotubes reinforcement Micromechanics of curing - monthly newsletter - monthly tel. conferences - thematically oriented TC - monthly lecture - tandem workshop Numerical Simulation ESW Materials & Processes Bremen - Toulouse ALM process simulation EADS IW D EADS IW UK EADS IW FR
14 Education New master degree program Computational Materials Science (CMS) New generation of highly qualified specialists with interdisciplinary competences for: - Materials Science - Process Engineering - Numerical Simulation Prof. Ploshikhin s part of CMS master degree program: - Material science (metals, polymers, ceramics, composites) 42 hours p.a. - Material structure and properties 28 hours p.a. - Macroscopic modeling (Finite Element Method / process simulation) 84 hours p.a. - Training macroscopic modeling (FEM commercial software tools) 56 hours p.a. Total: 210 hours p.a.
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