Umformung

Im Bereich der Umformsimulation werden Methoden für die Vorhersage des Umformverhaltens von textilen, imprägnierten und vorimprägnierten Halbzeugen entwickelt. Dabei liegen die Schwerpunkte auf trockenen Gelegen und Geweben, unidirektional verstärkten thermoplastischen Tapes (UD-Tapes) sowie auf der Kombination von textiler Drapierung und gleichzeitiger Infiltration innerhalb eines Prozessschritts, was besonders für das Nasspressen relevant ist. Zur makroskopischen Beschreibung des Halbzeugverhaltens im Prozesse geeignete Finite Elemente, Materialmodellen und Kontaktmodellen unter Verwendung des FE-Solvers Abaqus entwickelt. Hierfür steht zugleich die Charakterisierung der Deformationsmechanismen der Halbzeuge unter Prozessbedingungen im Fokus.

Um möglichst umfassende Untersuchungen zu ermöglichen setzten wir auf die bewährte Kooperation mit dem KIT-IAM-WK und dem Fraunhofer ICT  umso auf für neue Materialsysteme Materialkarten entwickeln zu können.

 

Forschungsschwerpunkte
  • Entwicklung von effizienten makroskopischen Modelle zur Vorhersage der Umformung ganzer Bauteile
  • Vorhersage von Umformeffekten und -defekten (z.B. Faserorientierung, Faltenbildung, Lückenbildung)
  • Entwicklung geeigneter Materialmodelle unter Berücksichtigung des anisotropen Membran- und Biegeverhalten von Halbzeugen
  • Thermomechanische und ratenabhängige Modellierung von UD-Tapes unter Berücksichtigung der Kristallisationskinetik (Abkühlung)
  • Abbildung einer starken, gekoppelten Fluid-Struktur-Interaktion für die Infiltration im Nasspressprozess
  • Effiziente Berücksichtigung von mesoskopischen Effekten (z.B. Faserbiegung) auf Makro-Ebene
  • Entwicklung von dreidimensionalen Modellierungsansätzen für die Umformsimulation zur Abbildung der Kompaktierung.

 

Forschungsprojekte
Ansprechpartner

M.Sc. Bastian Schäfer
Tel.: +49 721 608-41821
Email: bastian.schaefer∂kit.edu

 

M.Sc. Johannes Mitsch
Tel.: +49 721 608-45390
Email: johannes.mitsch∂kit.edu

 

M.Sc. Jan Paul Wank
Tel.: +49 721 608-45904
Email: jan.wank∂kit.edu

 

 

Bild FAST-LB
Gegenüberstellung Experiment und Simulation der Drapierung eines nähgewirktes UD-Geleges (UD-NCF)
Bild FAST-LB
Gegenüberstellung Experiment und Simulation des Thermoformens eines thermoplastischen UD-Tape-Laminats
Bild FAST-LB
Schematische Darstellung des Nasspressprozesses in der Simulation

Ausgewählte Veröffentlichungen im Forschungsfeld


Towards digital process simulation of closed injection pultrusion
Poppe, N.
2024, März 1. 17th World Pultrusion Conference (2024), Hamburg, Deutschland, 29. Februar–1. März 2024
Pultrusion process simulation - modelling of the injection and impregnation chamber
Poppe, N.; Wilhelm, M.; Kärger, L.
2024. Proceedings of the 2023 International Conference on Composite Materials, Belfast, 30th July - 4th August 2023. Ed.: B. Falzon, Queen’s University Belfast
Membrane behavior of uni- and bidirectional non-crimp fabrics in off-axis-tension tests
Schäfer, B.; Zheng, R.; Naouar, N.; Kärger, L.
2023. International Journal of Material Forming, 16 (6), Art.-Nr.: 68. doi:10.1007/s12289-023-01792-x
Entwicklung eines echtzeitfähigen virtuellen Laborprüfstands (Simulationsumgebung) für das szenariobasierte Testen und Validieren hochautomatisierter Fahrentscheidungs- und Steuerungssysteme von Rangierlokomotiven
Schäfer, S.; Cichon, M. G.
2023. Dresden Rad Schiene 2023 : 19. Internationale Schienenfahrzeugtagung Dresden : 1.-3. März 2023 mit begleitender Fachausstellung : Tagungsband, 108–110, DVV Media Group
Design concept of a repairable YASA axial flux machine with a hybrid cooling system
Schäfer, A.; Baranowski, M.; Springmann, M.; Hof, L.; Frölich, F.; Peter, A.; Parspour, N.; Fleischer, J.; Middendorf, P.; Kärger, L.; Michalowski, A.
2023. 12th International Conference on Power Electronics, Machines and Drives (PEMD 2023), 119–128, Institution of Engineering and Technology (IET). doi:10.1049/icp.2023.1987
Experimental and predictive analysis of the molding behavior of a PA6 glass mat thermoplastic (GMT)
Dörr, D.; Singh-Heer, N.; Xu, C.; Chang, T.; Clement-Thorne, B.; Gergely, R. C. R.; Okonski, D.; Henning, F.; Straatman, A. G.; Hrymak, A.
2023. The International Journal of Advanced Manufacturing Technology, 129 (3-4), 1159–1173. doi:10.1007/s00170-023-12017-5
Rheological characterization and macroscopic modeling and simulation of the molding process of a PA6 Glass Mat Thermoplastic (GMT)
Dörr, D.; Singh-Heer, N.; Gergely, R. C. R.; Schreyer, L.; Henning, F.; Straatman, A. G.; Hrymak, A.
2024. Composites Part A: Applied Science and Manufacturing, 176, Art.-Nr. 107780. doi:10.1016/j.compositesa.2023.107780
Pultrusion process simulation - modelling of the injection and impregnation chamber
Poppe, N.; Wilhelm, M.; Kärger, L.
2023. 23rd International Conference on Composite Materials (ICCM 2023), Belfast, Vereinigtes Königreich, 31. Juli–4. August 2023
Modeling of 3D fluid-structure-interaction during in-situ hybridization of double-curved fiber-metal-laminates
Poppe, C.; Kruse, M.; Kärger, L.
2023. Material Forming 26th International ESAFORM Conference on Material Forming (ESAFORM 2023) Krakau, Polen, 19.04.2023–21.04.2023, 219–230, Materials Research Forum LLC. doi:10.21741/9781644902479-24
Permeability and fabric compaction in forming of fiber metal laminates
Kruse, M.; Poppe, C. T.; Henning, F.; Ben Khalifa, N.
2023. Journal of Composite Materials, 002199832311757. doi:10.1177/00219983231175725
A unit-cell mesoscale modelling of biaxial non-crimp-fabric based on a hyperelastic approach
Zheng, R.; Schäfer, B.; Platzer, A.; Colmars, J.; Naim, N.; Boisse, P.
2023. Material Forming. Ed.: L. Madej, 285–292, Materials Research Forum LLC. doi:10.21741/9781644902479-31
Investigation of the compaction behavior of uni- and bidirectional non-crimp fabrics
Schäfer, B.; Zheng, R.; Philippe, B.; Kärger, L.
2023. Material Forming. Ed.: L. Madej, 331–338, Materials Research Forum LLC. doi:10.21741/9781644902479-36
A hyperelastic material model considering biaxial coupling of tension–compression and shear for the forming simulation of woven fabrics
Schäfer, F.; Werner, H. O.; Henning, F.; Kärger, L.
2023. Composites Part A: Applied Science and Manufacturing, 165, Art.-Nr.: 107323. doi:10.1016/j.compositesa.2022.107323
Investigation of the Membrane Behavior of UD-NCF in Macroscopic Forming Simulations
Schäfer, B.; Haas, S.; Boisse, P.; Kärger, L.
2022. Key Engineering Materials, 926, 1413–1422. doi:10.4028/p-2977b4
Towards 3D Process Simulation for In-Situ Hybridization of Fiber-Metal-Laminates (FML)
Poppe, C. T.; Werner, H. O.; Kruse, M.; Chen, H.; Ben Khalifa, N.; Henning, F.; Kärger, L.
2022. Key Engineering Materials, 926, 1399–1412. doi:10.4028/p-cr2tco
A Benchmark for Fluid-Structure Interaction in Hybrid Manufacturing: Coupled Eulerian-Lagrangian Simulation
Meyer, N.; Werner, H. O.; Seuffert, J.; Dietrich, S.; Poppe, C.; Krauß, C.; Kärger, L.
2021, Juli 21. 5th International Conference on Hybrid Materials and Structures (2022), Leoben, Österreich, 20.–22. Juli 2022
Flow-induced fiber displacement in non-bindered UD-NCF during Wet Compression Molding – Analysis and implications for process control
Albrecht, F.; Poppe, C.; Tiemann, T.; Sauerwein, V.; Rosenberg, P.; Henning, F.
2022. Composites Science and Technology, 228, Art.-Nr.: 109574. doi:10.1016/j.compscitech.2022.109574
Challenges in characterization of polylactic acid (PLA) for thermomechanical material modeling in material extrusion
Frölich, F.; Dörr, D.; Jackstadt, A.; Kärger, L.
2022, Juli 4. 11th European Solid Mechanics Conference (2022), Galway, Irland, 4.–8. Juli 2022
A Benchmark for Fluid-Structure-Interaction in Hybrid Manufacturing: Simulation with preCICE in OpenFOAM
Dietrich, S.; Seuffert, J.; Werner, H.; Meyer, N.; Poppe, C.; Krauß, C.; Kärger, L.
2022, Juni 9. 8th European Congress on Computational Methods in Applied Sciences and Engineering (ECCOMAS 2022), Oslo, Norwegen, 5.–9. Juni 2022
Optimisation of manufacturing process parameters for variable component geometries using reinforcement learning
Zimmerling, C.; Poppe, C.; Stein, O.; Kärger, L.
2022. Materials and Design, 214, Art.-Nr.: 110423. doi:10.1016/j.matdes.2022.110423
Material modelling of fabric deformation in forming simulation of fiber-metal laminates - A review on modelling fabric coupling mechanisms
Werner, H. O.; Schäfer, F.; Henning, F.; Kärger, L.
2021. ESAFORM 2021: 24th International Conference on Material Forming, 14-16 April, online, Art.-Nr.: 2056, Université de Liège. doi:10.25518/esaform21.2056
A sequential approach for simulation of thermoforming and squeeze flow of glass mat thermoplastics
Dörr, D.; Ivanov, S.; Gergely, R.; Meyer, N.; Henning, F.; Straatman, A. G.; Hrymak, A.
2021. ESAFORM 2021: 24th International Conference on Material Forming ; 14-16 April 2021, online, Art.-Nr.: 376, Université de Liège. doi:10.25518/esaform21.376
Process simulation of wet compression moulding for continuous fibre-reinforced polymers. Dissertation
Poppe, C. T.
2021, November 19. Karlsruher Institut für Technologie (KIT). doi:10.5445/IR/1000140011
Experimental and numerical investigation on the impact response of CFRP under 3-point-bending
Nebe, M.; Schmack, T.; Schaefer, T.; Walther, F.
2021. Composites Part C: Open Access, 4, Art.-Nr.: 100079. doi:10.1016/j.jcomc.2020.100079
Prediction of forming effects in UD-NCF by macroscopic forming simulation – Capabilities and limitations
Kärger, L.; Galkin, S.; Kunze, E.; Gude, M.; Schäfer, B.
2021. ESAFORM 2021 - 24th International Conference on Material Forming, ULiège Library. doi:10.25518/esaform21.355
Potential and challenges of a solid-shell element for the macroscopic forming simulation of engineering textiles
Schäfer, B.; Dörr, D.; Kärger, L.
2021. ESAFORM 2021 - 24th International Conference on Material Forming, ULiège Library. doi:10.25518/esaform21.883
Towards numerical prediction of flow-induced fiber displacements during wet compression molding (WCM)
Poppe, C.; Albrecht, F.; Krauß, C.; Kärger, L.
2021. ESAFORM 2021 - 24th International Conference on Material Forming, ID: 1938, ULiège Library. doi:10.25518/esaform21.1938
A 3D process simulation model for wet compression moulding
Poppe, C. T.; Krauß, C.; Albrecht, F.; Kärger, L.
2021. Composites Part A: Applied Science and Manufacturing, 145, Art.-Nr.: 106379. doi:10.1016/j.compositesa.2021.106379
On the applicability of thermoforming characterization and simulation approaches to glass mat thermoplastic composites
Dörr, D.; Gergely, R.; Ivanov, S.; Kärger, L.; Henning, F.; Hrymak, A.
2020. Procedia manufacturing, 47, 118–125. doi:10.1016/j.promfg.2020.04.148
Material modeling in forming simulation of three-dimensional fiber-metal-laminates - A parametric study
Werner, H. O.; Poppe, C.; Henning, F.; Kärger, L.
2020. Procedia manufacturing, 47, 154–161. doi:10.1016/j.promfg.2020.04.160
Methoden zur Umformsimulation von Endlosfaserverbunden mit ABAQUS
Dörr, D.; Schirmaier, F.; Joppich, T.; Fürst, T.; Kärger, L.; Henning, F.
2015. SIMULIA Regional User Meeting (2015), Aachen, Deutschland, 12.–13. November 2015
Thermomechanical analysis of thermoforming processes with continuously fibre-reinforced semi-crystalline thermoplastics
Dörr, D.; Joppich, T.; Kugele, D.; Henning, F.; Kärger, L.
2018. Materials Science and Engineering Congress (MSE 2018), Darmstadt, Deutschland, 26.–28. September 2018
Integrated process simulation as enabler for efficient and robust design of composites and hybrids
Dörr, D.; Fengler, B.; Hohberg, M.; Kärger, L.; Henning, F.
2018. Fraunhofer Representative Office Korea 10th Anniversary Technology Seminar (2018), Seoul, Südkorea, 8. November 2018
Advanced Macroscopic Modelling Approaches for FE Composite Forming Simulation Using Abaqus
Dörr, D.; Poppe, C.; Zimmerling, C.; Krauß, C.; Schäfer, B.; Henning, F.; Kärger, L.
2018. SIMULIA Regional User Meeting (2018), Hanau, Deutschland, 4. Dezember 2018
Iterative determination of the tailoring of blanks for a waste-free composite forming by means of finite element forming simulation
Dörr, D.; Lipowsky, L.; Schirmaier, F.; Kärger, L.; Henning, F.
2016. International Conference on Automotive Composites (ICAutoC 2016), Lissabon, Portugal, 21.–23. September 2016
Layerby- layer analysis of fiber orientation of formed continuously fiber-reinforced polymers based on computer tomographic (CT) scans
Dörr, D.; Schöttl, L.; Pinter, P.; Henning, F.; Kärger, L.
2019. Colloquium 602 – Composite manufacturing processes. Analyses, modelling and simulations (2019), Lyon, Frankreich, 13.–15. März 2019
An Iterative Approach for the Determination of Tailored Blanks for Waste-Free Composite Forming by Means of FE Forming Simulation
Dörr, D.; Lipowsky, L.; Schirmaier, F. J.; Kärger, L.; Henning, F.
2017. International journal of automotive composites, 3 (2-4, SI), 323–338. doi:10.1504/IJAUTOC.2017.091427
Zeit- und kosteneffiziente Prozess- und Produktentwicklung für den Hochleistungs-Faserverbundleichtbau im Rahmen der Nasspresstechnologie
Poppe, C.; Zimmerling, C.; Albrecht, F.; Hüttl, J.; Fial, J.; Engelfried, M.
2017, Januar 31. Marktplatz Leichtbau (2017), Ludwigsburg, Deutschland, 31. Januar 2017
Systematic approach for the development of an FE-based process simulation framework for wet compression moulding of continuously reinforced composites
Poppe, C.; Dörr, D.; Kärger, L.
2019, März 13. Colloquium 602 – Composite manufacturing processes. Analyses, modelling and simulations (2019), Lyon, Frankreich, 13.–15. März 2019
Zeit- und kosteneffiziente Prozess- und Produktentwicklung für den Hochleistungs-Faserverbundleichtbau mittels Nasspresstechnologie
Poppe, C.; Fial, J.; Kärger, L.; Carosella, S.; Albrecht, F.; Zimmerling, C.; Draskovic, M.; Engelfried, M.
2017, Mai 30. 4. Technologietag Hybrider Leichtbau (2017), Stuttgart, Deutschland, 30.–31. Mai 2017
Development of a modular draping test bench for analysis of infiltrated woven fabrics in wet compression molding
Albrecht, F.; Zimmerling, C.; Poppe, C.; Kärger, L.; Henning, F.
2019. Key engineering materials, 809, 35–40. doi:10.4028/www.scientific.net/KEM.809.35
On the relevance of thermomechanics and crystallization kinetics for FE thermoforming simulation of semi-crystalline thermoplastic tapes
Dörr, D.; Kugele, D.; Joppich, T.; Henning, F.; Kärger, L.
2019. Proceedings 22nd International ESAFORM Conference on Material Forming, ESAFORM 2019; Vitoria-Gasteiz; Spain; 8 May 2019 through 10 May 2019, Art.-Nr.: 020011, American Institute of Physics (AIP). doi:10.1063/1.5112516
Experimental and numerical investigation of the contact behavior during FE forming simulation of continuously reinforced composites in wet compression molding
Poppe, C.; Dörr, D.; Kraus, F.; Kärger, L.
2019. Proceedings of the 22nd International ESAFORM Conference on Material Forming ; Vitoria-Gasteiz, Spain, 8–10 May 2019. Ed.: L. Galdos, Art.-Nr.: 020002, American Institute of Physics (AIP). doi:10.1063/1.5112507
Numerical modeling of a hybrid forming process for three-dimensionally curved fiber-metal laminates
Werner, H. O.; Dörr, D.; Henning, F.; Kärger, L.
2019. Proceedings of the 22nd International ESAFORM Conference on Material Forming ; Vitoria-Gasteiz, Spain, 8–10 May 2019. Ed.: L. Galdos, Art.-Nr.: 020019, American Institute of Physics (AIP). doi:10.1063/1.5112524
Experimental and numerical investigation of the shear behaviour of infiltrated woven fabrics
Poppe, C.; Dörr, D.; Henning, F.; Kärger, L.
2018. Composites / A, 114, 327–337. doi:10.1016/j.compositesa.2018.08.018
A 2D modeling approach for fluid propagation during FE-forming simulation of continuously reinforced composites in wet compression moulding
Poppe, C.; Dörr, D.; Henning, F.; Kärger, L.
2018. Proceedings of the 21st International ESAFORM Conference on Material Forming : ESAFORM 2018 : Palermo, Italy, 23-25 April 2018. Ed.: L. Fratini, Art.Nr. 020022, American Institute of Physics (AIP). doi:10.1063/1.5034823
Modelling approach for anisotropic inter-ply slippage in finite element forming simulation of thermoplastic UD-tapes
Dörr, D.; Faisst, M.; Joppich, T.; Poppe, C.; Henning, F.; Kärger, L.
2018. Proceedings of the 21st International ESAFORM Conference on Material Forming : ESAFORM 2018 : Palermo, Italy, 23-25 April 2018. Ed.: L. Fratini, Art.Nr. 020005, American Institute of Physics (AIP). doi:10.1063/1.5034806
Modeling of the Non-Isothermal Crystallization Kinetics of Polyamide 6 Composites During Thermoforming
Kugele, D.; Dörr, D.; Wittemann, F.; Hangs, B.; Rausch, J.; Kärger, L.; Henning, F.
2017. Proceedings of the 20th International ESAFORM Conference on Material Forming, ESAFORM 2017, Ireland, Dublin, 26th - 28th April 2017, Art.Nr. 030005, American Institute of Physics (AIP). doi:10.1063/1.5007992
Modeling and validation of gripper induced membrane forces in finite element forming simulation of continuously reinforced composites
Poppe, C.; Dörr, D.; Kärger, L.; Henning, F.; Joppich, T.; Henning, F.
2017. Proceedings of the 20th International ESAFORM Conference on Material Forming, ESAFORM 2017, Ireland, Dublin, 26–28 April 2017, Art.Nr. 030002, American Institute of Physics (AIP). doi:10.1063/1.5007989
On the relevance of modeling viscoelastic bending behavior in finite element forming simulation of continuously fiber reinforced thermoplastics
Dörr, D.; Schirmaier, F. J.; Henning, F.; Kärger, L.
2017. Proceedings of the 20th International ESAFORM Conference on Material Forming, ESAFORM 2017, Ireland, Dublin, 26th - 28th April 2017, Art.Nr. 030003, American Institute of Physics (AIP). doi:10.1063/1.5007990
A Benchmark Study of Finite Element Codes for Forming Simulation of Thermoplastic UD-Tapes
Dörr, D.; Brymerski, W.; Ropers, S.; Leutz, D.; Joppich, T.; Kärger, L.; Henning, F.
2017. Procedia CIRP, 66, 101–106. doi:10.1016/j.procir.2017.03.223
Sensitivity of material properties on wrinkling behavior and fiber reorientation of thermoplastic UD-Tape laminates during forming analyzed by Finite Element forming simulation
Dörr, D.; Joppich, T.; Schirmaier, F.; Mosthaf, T.; Kärger, L.; Henning, F.
2016. 17th European Conference on Composite Materials, ECCM 2016, Munich, Germany; 26. - 30. June, 2016
A method for validation of finite element forming simulation on basis of a pointwise comparison of distance and curvature
Dörr, D.; Joppich, T.; Schirmaier, F.; Mosthaf, T.; Kärger, L.; Henning, F.
2016. 19th International ESAFORM Conference on Material Forming (ESAFORM) Nantes; France; 27- 29 April 2016. Ed.: F. Chinesta, 170011, American Institute of Physics (AIP). doi:10.1063/1.4963567