BMBF-funded research project: Energy efficient pultrusion process for the production of composite parts with a thermoset matrix in series applications.

Energy-efficient pultrusion process for the production of fiber composite components with thermoplastic matrix in series production.

Within this BMBF-funded research project, in which DYNAmore GmbH collaborates with partners from Steinhuder Werkzeugbau GmbH, Steeger Flechtmaschinen GmbH & Co. KG, Daimler AG, Thomas Technik GmbH, Heraeus Noblelight GmbH and Volume Graphics GmbH as well as the ITV Denkendorf, software tools for the process and serviceability simulation, the latter with focus on short time dynamics, of pultruded composite materials embedded in a thermoset matrix shall be developed.

The main objective of DYNAmore is primarily in generating a continuous simulation process chain for the pultrusion process. It is expected that the production of pultruded fiber composite components can be much better planned and controlled with such numerical tools, than at present. In particular, the possibility to simulate the entire process chain, starting from the simulation of different manufacturing processes, mapping of simulation results to the next step and finally getting better models for serviceability studies (e.g. crashworthiness investigations), has great potential for further optimizing parts in future. It is expected that such models will increase the predictability of the behavior of fiber reinforced pultruded profiles and hence the mechanical properties can be designed much more accurately towards the actual needs. For this, the finite element solver LS-DYNA will be adapted and developed further. Information from CT scans or from micro models (single filament modeling technique) will deliver basic data to feed a macroscopic model in order to ease the design in every day engineering practice.