Process optimization via process simulation

Powder Technology, Fluid Dynamics

By simulating powder technological processing steps and sequences, we make the manufacture of specifically shaped, defect-free components more accurate and efficient. An additional part of our focus as powder technology experts concerns the modeling and simulation of mechanisms and processes which involve complex fluids or fluids charged with particles. With all that we do as powder technology specialists, our goal is to improve products and processes, reduce development times and enable our clients to reduce costs. We use different simulation methods and a full range of materials to handle almost the entire range of granular material systems as well as particle-loaded fluids.

Powder Technology Process Chain Video                                       Abrasive Machining Simulation Tool Video

                                             

Topics

 

Pressing and Sintering Processes

 

When using powder technology for the forming and shaping of components, die compaction has been established for many materials (ceramics, hard metals, sintered steel, magnetic materials, pharmaceutical powders). Complex components place high demands on the pressing technology: typical problems are the warpage caused by the green density gradients as well as cracks caused when extracting the component from the die or by temperature gradients during the sintering process. The ...

 

Particle-based Process Modeling

 

SimPARTIX® is an innovative and high-performance simulation software developed by the Fraunhofer IWM. On the basis of physical models, SimPARTIX® can numerically study a vast range of materials during the manufacturing process or while in use. This typically generates a large amount of data on dynamic material behavior. Our detailed data analyses and visualizations give you a deeper understanding of the fundamental dynamics of your processes. This enables us to...

 

Ceramic Sheets and Multilayer Ceramic Structures

 

It used to be that numerical simulations for ceramic sheet producers were rarely used to improve the production process. For this reason, the Fraunhofer IWM developed a linked simulation model at the microstructure and tape caster level so that predictions can be made about the ceramic casting process, including the calculation of the particle orientation in the casting slurry and in the resulting product. This allows the process management for tape casting...

 

Spray Drying


In the ceramics industry spray drying is an important process for converting fine primary powders into bigger granules with better transport properties. To achieve a high quality end product requires good attributes, specifically in reference to the handling and compaction of the granulate. For this reason, the granules should preferably be spherical and possess a homogeneous density. At the Fraunhofer IWM, material models are linked using the discrete element method (DEM) and ...

 

Filling Processes


When die filling - the first step in the classical powder technological process chain – both the flow behavior of the powder or the design of the die, as well as that of the filling shoe, can result in inhomogeneous or incompletely filled cavities. This operation can be thoroughly examined in advance via computer simulation by means of SimPARTIX®, a simulation method based on DEM which was developed by powder technology specialists at the Fraunhofer IWM. In this regard, for example, the ...

 

Debinding


The debinding step is required to remove the organic binding additives from the green compacts as a prerequisite for sintering. This important processing step in powder technology is a time and energy intensive procedure during which damage can occur when the temperature profile is improperly or awkwardly designed. A simulation model developed at the Fraunhofer IWM makes it possible to calculate internal stresses resulting from the gaseous disintegration of products in components and to identify...

 

Surface Compression


When powder technological processes are employed to manufacture porous materials such as sintered steel, characteristic properties are exhibited which to be described requires specialized material modeling. At the Fraunhofer IWM, corresponding models based on the Gurson model (Gologanu, Ponte-Castaneda) are implemented in the finite element (FE) program ABAQUS®. This allows the simulation of final processing steps, such as surface densification of gear wheels ...

 

Magnetorheological Fluids


Magnetorheological fluids (MRF) consist of magnetizable solid particles in carrier fluid. When applying an external magnetic field the particles become magnetized and form chains along the field lines. As a result, the MRF changes within milliseconds from a liquid to a solid state. This is very useful for targeted industrial applications, for example, clutches, shock absorbers and brakes. At the Fraunhofer IWM, MRF are modeled under real-life operating conditions at the particle level. In this way, a detailed and ...

 

Silicon Wire Sawing


Industrially, multi-wire saws are used for the separation of silicon ingots. A steel wire is drawn over pulleys whose indentations guarantee a constant spacing of the wires. The sawing process is achieved by pressing the silicon ingot against the wire mesh, which is moistened with abrasive slurry. The slurry typically consists of polyethylene glycol and angular SiC grains. The challenge is to simultaneously minimize silicon kerf loss while maximizing sawing efficiency. At the Fraunhofer IWM, particle based ...

 

Publications regarding Powder Technology, Fluid Dynamics


Contributions to newspapers, books and conferences as well as dissertations and project reports...

Services

  • More efficient production of precisely shaped, defect-free parts and components
  • Better understanding of the relationships and connections between the properties and the manufacturing conditions that surround your products
  • Cost reductions for the process of manufacturing powder technology components
  • Shortened development times through the use of optimized granular materials and complex, particle-laden fluids