Precision Enhancement in Melt-Based Manufacturing Processes
The SFB 1120 is dedicated to optimizing component precision through comprehensive analyses of melt formation, dynamics, and solidification in melt-based production processes.
SFB 1120 is concerned with increasing precision in melt-based manufacturing processes. This is done by looking at the entire process cycle consisting of melt formation, melt dynamics within the process and melt solidification. Since the sub-processes that take place occur in a local area of the component or during the shaping of the entire component, there are different orders of magnitude, which are dealt with in two project areas.
Through the close cooperation between different institutes of RWTH Aachen University within the two project areas, the different approaches and perspectives can contribute to a holistic understanding. In addition, synergies result from the different sub-projects, which contribute to achieving a higher prediction accuracy and thus make moulded parts producible without correction loops or subsequent machining.
© IKV
The SFB 1120 has been in its final funding period since June 2022 and the focus in the two project areas and the subprojects is now on process control and compensation. IKV is also represented in SFB 1120 in the third funding phase with three subprojects on minimising the warpage of injection-moulded components:
Sub-project B01: Algorithms for the design of a temperature control layout for injection moulds taking into account the local cooling requirements
The warpage of injection-moulded components can be minimised during production by the correct design of the cooling channel. The development of an individual automated cooling channel design with the help of an algorithm should help to locally dissipate heat from hotspots much better. The focus this year was on adapting the methodology developed for the production of straight, close-to-contour cooling channels. This places the focus on classic and established manufacturing processes in mould making. In addition, the methodology will be extended to anisotropic and engineering plastics.
Sub-project B03: Self-optimising process control strategies for highly segmented mould temperature control in injection moulding
Another factor influencing the resultant warpage is the mould temperature control. This can be controlled via a model-predictive control strategy (MPC) of the specific volume. This requires a highly segmented dynamic mould control. The control of the moulding precision for complex geometries and engineering thermoplastics is to be achieved, among other things, through the use of ceramic heating layers. This year, a routine for placing the ceramic heating layers in the mould was developed by simulation and applied to the design of the practical demonstrator. The routine was also used to identify suitable process points with the lowest possible distortion.
Sub-project B04: Analysis of the thermal coupling of melt, microstructure and mould for the precise prediction of shrinkage and warpage in the injection moulding process
Process control and tool design also have an effect on the structure and morphology of the moulded part, and thus influence warpage. In order to precisely predict this warpage by simulation, it is necessary to link together different simulations. The already successfully validated multi-scale simulation chain, including the homogenisation approach, was transferred to an XNS solver this year and validated in a self-consistent iterative multi-scale simulation. Furthermore, the phenomenon of post-crystallisation and its influence on the final component distortion was addressed in terms of process technology and measurement technology.
Project Data and Funding
Project Duration: 01.07.2014 – 30.06.2026
Deutsche Forschungsgemeinschaft (DFG)
Project Partners & Funding
