@inproceedings{MartinsWagnerWagnerHaufeetal., author = {Martins-Wagner, Magda and Wagner, Marcus and Haufe, Andr{\´e} and Liebold, Christian}, title = {A Graphical User Interface for Simulating Resin-Transfer-Molding Combining LS-DYNA and OpenFOAM}, series = {10th European LS-DYNA Conference 2015, W{\"u}rzburg, Germany}, booktitle = {10th European LS-DYNA Conference 2015, W{\"u}rzburg, Germany}, abstract = {The paper describes parts of the joint research project Swim-RTM including several industrial and academic partners. Its goal is to combine LS-DYNA and the open-source CFD solver OpenFOAM to simulate the production process of continuous fiber-reinforced plastics, particularly the resin-transfer-molding (RTM) process, in which the layers of dry fabric (unidirectional or woven) are formed in the mold (draping) and then filled with liquid resin with high pressure at injection points. Through a combined analysis of both the structural mechanical and the fluid dynamical phases, a better prediction and thereby optimization of the textile components properties as well as injection points can be achieved, improving the manufacturing process. The draping simulation of the fabric layers is carried out with LS-DYNA, while the injection simulation of the matrix material is performed in full 3D with OpenFOAM. A key question in this research project is how local porosities can be derived from the structural computation in the draping step. The purpose of the presented subproject is to develop a graphical user interface (GUI) to enable the simulation of the entire RTM process of long-fiber-reinforced components including the transfer of results between the draping and injection phases. The complete simulation task is relatively complex and involves several software packages, meaning a high effort for the user to get familiarized with. To circumvent this, the GUI aims at requiring from the user only the minimum necessary input data, creating and running the simulation and mapping tasks in the background, and showing graphically all demanded intermediate and final results. For the draping step several current fabric materials such as *MAT_034, *MAT_234, *MAT_235, *MAT_249 are available. Several modelling techniques for the composite setup are also conceivable, including a workflow similar to metal forming applications. In the injection step the fabric is modelled as a porous medium and different transport models and liquid resin types are at hand. For the data transfer between the draping and injection models, i.e. the mapping of data between shell and volume meshes within the developed GUI, first the OpenFOAM volume mesh is converted to LS-DYNA format and the necessary passing parameters are extracted from the output files, then the mapping tool DYNAmap [3] from DYNAmore GmbH is invoked, and finally the OpenFOAM command files are created. After the injection simulation is started and successfully terminated, information, such as the distribution of air inclusions or the shear stress distribution to analyze the reorientation of component fibers, is available and can be transferred from the 3D fluid mesh to an LS-DYNA shell mesh for further computations, for instance a crash simulation. This backward data mapping between volume and shell meshes can then be performed inside the GUI.}, language = {en} } @techreport{ThumannSwidergalWagner, author = {Thumann, Philipp and Swidergal, Krzysztof and Wagner, Marcus}, title = {Experimentelle Ermittlung von Materialkennwerten und numerische Untersuchungen an einem gef{\"u}llten Elastomer}, series = {Forschungsbericht 2015 / Ostbayerische Technische Hochschule Regensburg}, journal = {Forschungsbericht 2015 / Ostbayerische Technische Hochschule Regensburg}, editor = {Baier, Wolfgang}, organization = {Ostbayerische Technische Hochschule Regensburg}, isbn = {978-3-00-048589-3}, pages = {49 -- 50}, language = {de} } @inproceedings{ThumannSwidergalWagner, author = {Thumann, Philipp and Swidergal, Krzysztof and Wagner, Marcus}, title = {Calculation and validation of material tests with specimens made out of filled elastomers}, series = {10th European LS-DYNA Conference 2015, W{\"u}rzburg}, booktitle = {10th European LS-DYNA Conference 2015, W{\"u}rzburg}, abstract = {In deep-drawing dies for steel sheet parts of car bodies huge masses are moved. To prevent vibrations, which occur by sudden acceleration or stopping of those masses, elastomeric tubular dampers [1] are used. The dampers are made out of carbon filled elastomers. A good knowledge about the material behaviour of metals is available. But for the numerical investigation of complete deep-drawing dies the elastomeric dampers must be taken into account, too. To characterize the material behaviour of the elastomers tensile tests and pressure tests were carried out. The received material data from the tests were read into LS-DYNA [2]. Simulation models of the tensile test and the pressure test were created for LS-DYNA according to the real dimensions and boundary conditions. For validation purposes, calculations of loading cycles were done to enable a comparison between test data and simulation results. For the calculations the implemented material model *MAT_SIMPLIFIED_RUBBER_WITH_DAMAGE (*MAT_183) was used. The comparison shows a good fitting between the test data and the calculation results with respect to the mechanical material behaviour by using this material model in single loading cases. The settings from the simulations of material tests were transferred to simulations of dampers, which are used in deep-drawing dies.}, language = {en} } @misc{ScharfenbergMottokArtmannetal., author = {Scharfenberg, Georg and Mottok, J{\"u}rgen and Artmann, Christina and Hobelsberger, Martin and Paric, Ivan and Großmann, Benjamin and Pohlt, Clemens and Wackerbarth, Alena and Pausch, Uli and Heidrich, Christiane and Fadanelli, Martin and Elsner, Michael and P{\"o}cher, Daniel and Pittroff, Lenz and Beer, Stefan and Br{\"u}ckl, Oliver and Haslbeck, Matthias and Sterner, Michael and Thema, Martin and Muggenthaler, Nicole and Lenck, Thorsten and G{\"o}tz, Philipp and Eckert, Fabian and Deubzer, Michael and Stingl, Armin and Simsek, Erol and Kr{\"a}mer, Stefan and Großmann, Benjamin and Schlegl, Thomas and Niedersteiner, Sascha and Berlehner, Thomas and Joblin, Mitchell and Mauerer, Wolfgang and Apel, Sven and Siegmund, Janet and Riehle, Dirk and Weber, Joachim and Palm, Christoph and Zobel, Martin and Al-Falouji, Ghassan and Prestel, Dietmar and Scharfenberg, Georg and Mandl, Roland and Deinzer, Arnulf and Halang, W. and Margraf-Stiksrud, Jutta and Sick, Bernhard and Deinzer, Renate and Scherzinger, Stefanie and Klettke, Meike and St{\"o}rl, Uta and Wiech, Katharina and Kubata, Christoph and Sindersberger, Dirk and Monkman, Gareth J. and Dollinger, Markus and Dembianny, Sven and K{\"o}lbl, Andreas and Welker, Franz and Meier, Matthias and Thumann, Philipp and Swidergal, Krzysztof and Wagner, Marcus and Haug, Sonja and Vernim, Matthias and Seidenst{\"u}cker, Barbara and Weber, Karsten and Arsan, Christian and Schone, Reinhold and M{\"u}nder, Johannes and Schroll-Decker, Irmgard and Dillinger, Andrea Elisabeth and Fuchshofer, Rudolf and Monkman, Gareth J. and Shamonin (Chamonine), Mikhail and Geith, Markus A. and Koch, Fabian and {\"U}hlin, Christian and Schratzenstaller, Thomas and Saßmannshausen, Sean Patrick and Auchter, Eberhard and Kriz, Willy and Springer, Othmar and Thumann, Maria and Kusterle, Wolfgang and Obermeier, Andreas and Udalzow, Anton and Schmailzl, Anton and Hierl, Stefan and Langer, Christoph and Schreiner, Rupert}, title = {Forschungsbericht 2015}, editor = {Baier, Wolfgang}, address = {Regensburg}, organization = {Ostbayerische Technische Hochschule Regensburg}, isbn = {978-3-00-048589-3}, doi = {10.35096/othr/pub-1386}, url = {http://nbn-resolving.de/urn:nbn:de:bvb:898-opus4-13867}, language = {de} } @article{SwidergalLubesederWurmbetal., author = {Swidergal, Krzysztof and Lubeseder, Christian and Wurmb, Ingo von and Lipp, Arnulf and Meinhardt, Josef and Wagner, Marcus and Marburg, Steffen}, title = {Experimental and numerical investigation of blankholder's vibration in a forming tool}, series = {Production Engineering - Research and Development}, volume = {9}, journal = {Production Engineering - Research and Development}, number = {5-6}, publisher = {Springer}, issn = {0944-6524}, doi = {10.1007/s11740-015-0640-9}, pages = {634}, abstract = {In order to achieve the energy and efficiency goals in modern automotive press shops, press systems with increasingly high stroke rates are being implemented (Meinhardt in proceedings of ACI forming in car body engineering. Bad Nauheim, Germany 2012). As a side effect, the structural dynamic loads on the press and especially on the forming tool increase. Hence, to design reliable and withstanding forming tools, a detailed knowledge of the vibrations and resulting critical loads is essential. In this paper, the main focus is put on the vibration of the blankholder—the heaviest moving component in the forming tool. To predict those vibrations, a coupled multibody-finite element simulation (MBS-FEM) is conducted, which combines rigid and elastic modeling approaches. Also, an experimental validation of the blankholder vibration under operational load is carried out. To compare the numerical and experimental results—both in time and frequency domain—an 1/3-octave analysis of a blankholder's vibrational speed is performed. The test measurements agree well with the MBS-FEM simulation.}, language = {en} } @inproceedings{SwidergalWagnerLubesederetal., author = {Swidergal, Krzysztof and Wagner, Marcus and Lubeseder, Christian and Wurmb, Ingo von and Meinhardt, Josef and Marburg, Steffen}, title = {Finite element simulation of blankholder's lift-off in a deep drawing tool using Abaqus/Standard}, series = {SIMULIA Community Conference, 19 - 21 May 2015, Berlin, Germany}, booktitle = {SIMULIA Community Conference, 19 - 21 May 2015, Berlin, Germany}, abstract = {In the deep drawing tools for forming car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the deep drawing tool and on the press. Therefore a detailed knowledge about the blankholder's lift-off event is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of a blankholder's lift-off in a selected automotive deep drawing tool is presented enabling identification of regions of critical stresses. The FEM model is built within the Abaqus/CAE environment and solved with Abaqus/Standard. Each dynamic analysis is preceded by a static analysis where the gravity load is applied and the lifting bolts are pre-stressed. A special emphasis is put on modeling the elastomer dampers, which are installed between lifting bolts and the blankholder to avoid hard impacts during the lift-off event. Those dampers are modelled using a hyperelastic material with hysteresis. In addition, an experimental validation of a blankholder's vibration under operating loading was carried out. The simulation results are in good agreement with the measurements.}, language = {en} } @inproceedings{SwidergalLubesederWurmbetal., author = {Swidergal, Krzysztof and Lubeseder, Christian and Wurmb, Ingo von and Lipp, Arnulf and Meinhardt, Josef and Wagner, Marcus and Marburg, Steffen}, title = {Structural analysis of an automotive forming tool for large presses using LS-DYNA}, series = {10th European LS-DYNA Conference, W{\"u}rzburg}, booktitle = {10th European LS-DYNA Conference, W{\"u}rzburg}, language = {en} }