Integrated assessment of processing steps, material microstructures and component behavior

ICME applications

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Sheet metal forming

Integral computer simulation of sheet metal forming process
(Hot rolling – cold rolling – annealing – deep drawing – crash)

Prediction of material behavior during the manufacturing process, including the resultant properties of the semi-finished product, as well as calculations of the tolerances and behavior during forming and the resulting end-product component properties.

Sheet metal forming simulation topics

Degree of forming, thermo-mechanical process controls, phase transformation, flow behavior, texture development, hardening, damage.

Sheet metal forming methods and models

Various plasticity, recrystallization, phase formation and damage models on the micro and macro scale.

Contact
Dr. Dirk Helm
Phone +49 761 5142-158

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Powder technology

Integral computer simulation of powder technology process
(Filling – compression – debinding – sintering – redensification)

Virtual optimization of individual processing operations with the aim of tolerance assessment and producing crack-free and precisely contoured components.

Powder technology processing 3D computer simulation topics

Particle form, pore morphology, porosity distribution.
Process parameters: feeder motion, tamper motion, temperature profile, contact pressure.

Powder technology methods and models

Discrete (DEM) and continuous (FEM) simulation methods, various contact and plasticity models (incompressible plasticity irrespective of rate, porous plasticity irrespective of rate, anisotropic porous plasticity) as well as flow and diffusion models.

Contact
Dr. Torsten Kraft
Phone +49 761 5142-248

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Mikro- und Nanofluidik

Integral computational analysis, assessment and design of micro and nano fluidic systems
(Surface modifications – wetting behavior - mixing/separating behavior)

Calculation and prediction of the mixing and separating behavior of complex liquids due to customized surface properties and outer fields (e.g. lab-on-a-chip systems).

Micro and nano fluidics 3D computer simulation topics

Flow field, viscosity, particle trajectories, wetting behavior due to micro and nano-structured surfaces, fluidic transport processes on the micro and nano scale, development of microfluidic components.

Methods and fluidics modeling software

Description of liquid phases using the finite volume method (FVM) within the context of computational fluid dynamics (CFD) or smoothed particle hydrodynamics (SPH), particle-fluid systems and multiscale modeling of microfluidic systems by coupling CFD to discrete elements method (DEM) and molecular dynamics (MD).

Contact
Dr. Adham Hashibon
Phone +49 761 5142-287

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Tribology of fluid and granular systems

Integral computational assessment and design of fluid and granular systems
(Wear protection – surface treatment – separation – magnetorheology – bio-fluidics)

Assessment and prediction of the flow properties of bulk dry goods, suspensions, polymer solutions and switchable fluids as well as surface development in tribological applications and biosystems.

Fluid and granular systems computer simulation topics

Rheology, friction, magnetism, plasticity, damage, erosion, abrasion, deposition.

Tribology of fluid and granular systems methodology and models

Description of liquids using smoothed particle hydrodynamics (SPH) or the finite volume method (FVM), of dry bulk goods and suspended particles using the discrete element method (DEM) and of solid bodies using SPH or DEM.

Contact
Dr. Claas Bierwisch
Phone +49 761 5142-347

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Cellular materials and solid foams

Integral computational assessment of components made from cellular materials and solid foams

Assessment and prediction of microstructural development during foaming, and the calculation and optimization of effective material data that corresponds to requirements at the component level. Integrated numerical computer simulations from the microstructural through the macroscopic (component) level.

Cellular materials and solid foams 3D computer simulation topics

Elasticity, plasticity, creep, acoustic properties and expected variance, thermal and thermomechanical properties.

Cellular materials and solid foams methodology and modeling

Thermo-mechanical models as well as probability analysis for mechanisms on the micro and macro scales; homogenization approaches.

Contact
Dr. Jörg Hohe
Phone +49 761 5142-340

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Long fiber reinforced thermoplastics

Integral computational assessment of short and long fiber reinforced thermoplastics (LFT)

Assessment and analysis of materials and/or components under consideration for the process-related microstructure. Optional functionalization with metals or endless fibers (multi material / hybrid systems).

Short and long fiber reinforced thermoplastics 3D computer simulation topics

Mold filling, local process-related fiber orientation, density and length distribution, residual stresses.
Strength, creep, plasticity, strain rate and temperature effects in relation to the manufacturing process.

Short and long fiber reinforced thermoplastics methods and modeling

Microstructural models, homogenization techniques, development of appropriate effective material models, probabilistic approaches.

Contact
Dr. Jörg Hohe
Phone +49 761 5142-340

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Heat treatment processes

Assessment and optimization of heat treatment processes for customized component properties

Link between heat treatment process parameters and the mechanical component properties and component lifetime under thermomechanical fatigue loading.

Heat treatment processes 3D computer simulation topics

Evolution of precipitates and their distribution via the thermodynamic extremum principle in relation to the transient temperature fields during the heat treatment process.
Growth of small fatigue cracks under thermomechanical fatigue loading.

Heat treatment processes methodology and modeling

Thermodynamic-kinetic models, phenomenological evolution equations for microstructural features & recrystallization, RVEs for flow surfaces, viscoplastic material models for describing mechanics, mechanism-based models for small fatigue crack growth under thermomechanical fatigue loading.

Contact
Dr. Christoph Schweizer
Phone +49 761 5142-382

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Crash safety of cast components

Evaluation and optimization of casting processes for maximum cast component crash safety

Link between casting and crash simulations to improve the prediction of crash properties.

Crash safety of cast components 3D computer simulation topics

Porosity and microstructure distribution as well as micro defects.

Crash safety of cast components methodology and modeling

Microscopic material models and micromechanical failure models with internal variables that account for microstructure, and cell model calculations for investigating the stochastic effects on pore morphology.

Contact
Dr. Dong-Zhi Sun
Phone +49 761 5142-193

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Crash safety of extruded components

Assessment and optimization of extrusion process for maximum component crash safety

Link between extrusion and crash simulations to improve the prediction of crash properties, modification of extrusion tools in order to define the microstructural distribution in semi-finished products.

Crash safety of extruded components 3D computer simulation topics

Process parameters as well as the resultant microstructure such as deformed and recrystallized grains and exclusions.

Component crash safety methodology and modeling

Material laws dependent on temperature and expansion rates that account for stress states and friction models at high levels of hydrostatic stress.

Contact
Dr. Dong-Zhi Sun
Phone +49 761 5142-193

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Joints

Evaluation, assessment and optimization of joints

Coupling between joining process simulations and load bearing capacity simulations under crash loading conditions to parameterize simplified finite element models of joints; welding simulations for various welding processes to minimize residual stresses and distortion.

Joining process 3D computer simulation topics

Prediction of load bearing capacity, calculation of distortion and residual stresses.

Joining process methodology and modeling

Microscopic material models and micromechanical/empirical failure models, flow and failure models for adhesives, modeling of substitute joins across surfaces, lines and at isolated points.

Contact
Dr. Silke Sommer
Phone +49 761 5142-266

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New material functions and substitute materials

Design of new material functions and the search for and implementation of new substitute materials
(Hard magnets, transparent and conducting oxides, piezoelectrics and thermoelectrics)

Calculation of macroscopic (magnetic, electric, optical, mechanical) material functions from microscopic material data.

New material functions 3D computer simulation topics

Relationships between crystal structure, crystal composition and local magnetic moments, relationships between the dimensionality of crystal defects and electronic states in the band gaps of oxidic semiconductors, or the effects of crystal symmetries, of atomic defects and dopants, as well as of grain and phase boundaries on ferroelectric polarization.

New material functions and substitute materials methodology and modeling

First principles and semi-empirical electronic-structure calculation methods (density functional theory and tight binding theory), spin models and micro-magnetism for hard magnets, band structure and effective mass models for oxidic (semi-)conductors and for thermoelectrics as well as phase field theory and micromechanics for piezoelectrics.

Contact
Prof. Dr. Christian Elsässer
Phone +49 761 5142-286

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Coating processes

Optimization of coating processes for customized tribological layers

Link between coating parameters (species, energies, angle of impact, layer temperature), layer structure and mechanical/tribological layer properties (grading, wear resistance, friction).

Coating processes 3D computer simulation topics

Layer performance as a result of growth conditions, post-processing and running-in.

Coating processes methodology and modeling

Molecular dynamics of the deposition process linked to topographic continuum models, plasticity models for the layer and continuum models for wear.

Contact
Prof. Dr. Michael Moseler
Phone +49 761 5142-286

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Multi-scale experiments

Multi-scale experiments are carried out in parallel to the computational experiments

Extraction of small material volumes (e.g. coating materials, hardened-on layers).

Static and dynamic mechanical investigations (e.g. tensile, compression and flexural tests to determine strength, fatigue life or fracture toughness).

Static and dynamic trials under different atmospheric and temperature conditions.

Contact
Prof. Dr. Chris Eberl
Phone +49 761 5142-495

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