Working Group Modelling and Simulation

 

Working group M1: Modelling of energy transfer at interfaces

Responsible: Ilkin Alkhasli


When were meetings held?

10.07.2019 / 26.08.2019 / 06.02.2020


Which questions are currently being worked on?

  • Use of passive thermal barrier coatings in casting and injection moulding
  • Use of active heating conductor layers in casting and injection moulding

Filling simulations of casting and injection moulding

  • Reduction of distortion during injection moulding due to passive thermal insulation
  • Active temperature control during casting and injection moulding through heat conductor layers

Experimental validation of the simulation results using manufactured prototypes

  • Thermocamera recordings during injection moulding
  • Long-term resistance of passive and active coatings
  • Evaluation and publication of the findings


When should a publication be made in this regard?

Topic Application of plasma sprayed coatings in injection molding and permanent mold casting in cooperation with subprojects A10, A12, B1, B3, B8 and B9

Topic Application of electrical heater coatings in injection molding and permanent mold casting in cooperation with subprojects A10, A12, B1, B3, B8 and B9

 

Working group M2: Process model for melt pool dynamics and multi-phase modelling of the melt

Responsible: Christoph Schöler


When were meetings held?

17.01.2019 / 20.03.2019 / 27.05.2019


Which questions are currently being worked on?

  • Evaporation modelling (A3, A4, A9)
    • Evaporation in welding capillary (A3)
    • Evaporation on top of the workpiece (A4) not relevant at first
    • Evaporation on melt front (A9)
    • Problem: large driving forces small time increments
  • Modelling the solidification of thin films (A9, A10)
    • Methods from A9 not applicable in A1
    • Problem: spatial integration via melting film, singularities
    • Reverse...?
  • Solidification modelling (A3, A4, A9, A10, B5)
    • Extended enthalpy method with Darcy term in momentum equation
    • Momentum source method
    • Enthalpy-porosity method
    • Mixture model
    • Current status in the TP
    • A10 and B5 have already implemented the method
    • A3 and A9 are in the process...
    • Interface to AK M3


When should a publication be made in this regard?

Publications from cooperations

  • A3, A4: Mokrov et al., Simulation of laser and MSG welding for the welding structure simulation, Simulation Forum Weimar (tbp 2020)
  • A3, A4, A9: Evaporation modelling in molten bath simulations (planned )
  • AK M4: Solidification modelling in melt pool simulations (under discussion)


Publications with information flow from the working group

  • A3: Schöler et al, Modeling and simulation of laser micro welding, LiM 2019 (2019)


Feedback from the subproject:

"The working points jointly defined in the working groups and the mutual controlling of progress at the meetings have contributed significantly to the progress and development of subproject A4. In particular, the AKs supported a wide range of topics which might have been out of focus without the AKs". M. Simon

 

Working group M3: Modelling and simulation of solidification, distortion and residual stresses

Responsible: Dr. G. Laschet


When were meetings held?

  • 09.01.2019: Topic among others modelling of the filling process, heat transfer and solidification of semi-crystalline polymers on the macroscale
  • 29.10.2019: Topic: Influence of the degree of crystallization and lamella design on the effective mechanical properties of a PP component

- DSC measurements of the degree of crystallization over the component thickness

- The lamella design depends not only on the degree of crystallization but also on the distance from the spherulite center a

  • 04.12.2019: self-consistent micro-macro simulation (B7)

- iterative improvement of the casting simulation of an A356 cup by coupled microstructure simulation considering the Sr refinement


Which questions are currently being worked on?

Modelling of the solidification of semi-crystalline polymers

 

Working group M4: Efficient numerical methods

Responsible: Violeta Karyofylli


When were meetings held?

08.11.2018 / 11.12.2018 / 14.01.2019 / 05.02.2019 / 14.03.2019 / 29.03.2019 / 09.04.2019 / 17.05.2019 / 04.07.2019 / 05.08.2019 / 23.09.2019 / 07.10.2019 / 23.10.2019 / 21.11.2019 / 21.01.2020

Which questions are currently being worked on?

  • Drop separation in MSG welding combined with adaptive time refinement (TP A4, B5)
  • Solidification/melting: level set method vs. enthalpy porosity method (TP A3, A10, B5, B7)
  • Stokes' flow around spheres: a comparison of different numerical methods and boundary conditions (TP A3, B5, B7)


When should a publication be made in this regard?

Subject Application of space-time refinement for droplet formation during GMA welding in cooperation with subprojects A4 and B5

Topic Axisymmetric two-phase flow simulations on space-time meshes in cooperation with subprojects A4 and B5

Topic Space-Time Discretization using the example of drop separation in MSG welding (2019) in cooperation with subprojects A4 and B5


Topic Phase Transition: Enthalpy-Porosity Method vs. Level-Set Method on 4D Simplex Space-Time Meshes

Topic 4D Simplex Space-Time Meshes for Production Engineering Applications

Subject Stokes flow around spheres: a comparison of different numerical methods