Mobility in Science and Engineering

In the “Mobilise” focus area Production and Lightweight Construction, a research group consisting of scientific staff from the Institute for Machine Tools and Manufacturing Technology (IWF) at TU Braunschweig and the Institute for Forming Technology and Machines at Leibniz Universität Hannover is working on simulation methods for the production and process chain design of hybrid components. Both research institutes are closely networked via the Open Hybrid LabFactory (OHLF) in Wolfsburg. The focus of the research activities is on the factory of the future. Here, classical process simulation using the finite element method is linked with process chain simulation and data-based methods for a continuous virtual product view. The aim of the research group is to develop an innovative multi-layer simulation environment that couples different individual models. This coupling in turn also serves a process or process chain simulation in the sense of a holistic product view in order to address technological, economic and ecological research questions. In the context of OHLF, mainly hybrid forming and injection moulding processes are considered. Based on real manufacturing processes, process and machine data are collected and evaluated using data analytics. In addition, modern simulation methods, e.g. the finite element method, are used to investigate the manufacturing processes. By matching the real component with the virtual component as well as the process and machine data, simulation and process are optimised, resulting in improved virtual and digital process validation. As an example, for the virtual functional design of hybrid components, it is essential to consider the microstructure and the manufacturing process in the structural simulation. Transferring the results from the process simulation to the structural component provides a detailed model for stress analysis. By coupling the results back into the process simulation and into the structural design of the component, the process and component are adapted to meet the required part demands.