Integrated Simulation of the Process Chain Composite Extrusion – Milling – Welding for Lightweight Frame Structures

Zäh, M.1, a; Tekkaya, A. E.2, b; Biermann, D.3, c; Zabel, A.3, d; Langhorst, M.1, e; Schober, A.1, f; Kloppenborg, T.2, g; Steiner, M.3, h; Ungemach, E.3, i

Institut für Werkzeugmaschinen und Betriebswissenschaften, Technische Universität München, Boltzmannstr.15, 85747 Garching
Institut für Umformtechnik und Leichtbau, Technische Universität Dortmund, Baroper Str. 301, 44227 Dortmund
Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund

a); b); c); d); e); f); g); h); i)


Generally, the manufacturing of lightweight frame structures involves various processes that yield the final product. Simulation methods can be used to optimise the different process steps. When chaining these process steps together in the simulation, software interfaces become necessary to realise an integrated virtual process chain. In this paper two approaches are presented that solve this issue and demonstrate it for an exemplary part. Different software tools with appropriate interfaces and the use of only one software tool for the simulation of the whole process chain are investigated respectively. The results of both approaches are analysed and relevant conclusions are deduced.


simulation, process chain, lightweight frame structures, software interfaces, composite material


Production Engineering. Research and Development, 3 (2009) 4-5, S. 441-451, doi: 10.1007/s11740-009-0190-0