{"id":12443,"date":"2026-05-11T14:49:06","date_gmt":"2026-05-11T12:49:06","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/tsg-mikro-sim-multi-scale-foam-simulation\/"},"modified":"2026-05-12T16:14:39","modified_gmt":"2026-05-12T14:14:39","slug":"tsg-mikro-sim-multi-scale-foam-simulation","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/tsg-mikro-sim-multi-scale-foam-simulation\/","title":{"rendered":"TSG Mikro Sim &#8211; Multi-scale foam simulation"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_50a035d7028a0de43d5c6bfcdaaa9c5c .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_50a035d7028a0de43d5c6bfcdaaa9c5c .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_50a035d7028a0de43d5c6bfcdaaa9c5c\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Microscale model for multiscale simulation of thermoplastic foam injection moulding                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Physically foamed thermoplastic injection moulded components have many advantages over compact parts. However, precise technical design using structural simulation is not possible, as effects such as cell deformation due to shear effects, coalescence and bubble collapse are not taken into account. This is where the DFG project comes in, investigating how these effects can be modelled and calculated using a micro-simulation of foaming in the injection moulding process.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/HO4776-81-1.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/HO4776-81-1-748x499.png 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/HO4776-81-1-1536x1024.png 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/HO4776-81-1-768x512.png 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"1024\" alt=\"HO4776-81-1\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: Simulated and measured cell structure based on interactions between bubbles, coalescence and deformation due to shear.<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">As a basis for a micro-scale foaming model, mathematical and physical descriptions for nucleation and bubble growth were researched and adapted for injection moulding. Multiphase flow simulation for compressible media was developed in the open-source software OpenFOAM. In addition to shear viscosity, strain viscosity is relevant for modelling bubble growth, which is why a Phan-Thien-Thanner model was used and fitted to describe viscoelasticity in comparison to conventional purely viscous models.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The microsimulations show real deformation phenomena caused by shear and interactions between bubbles as influencing factors on the final cell geometry and coalescence (Fig. 1). The distribution of bubble size, orientation and aspect ratio can also be interpolated for other positions by selecting suitable support points.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the DFG for funding the project (funding reference HO 4776\/81-1) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.09.2022 &#8211; 31.01.2026<\/p>\n\n\n<section id=\"logo-bar-block_7c8bb838055fbfb14ec6616edc35a4c7\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/12\/Logo-DFG-748x591.png 748w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"748\" height=\"591\" alt=\"Logo-DFG\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>Physically foamed thermoplastic injection moulded components have many advantages over compact parts. However, precise technical design using structural simulation is not possible, as effects such as cell deformation due to shear effects, coalescence and bubble collapse are not taken into account. This is where the DFG project comes in, investigating how these effects can be modelled and calculated using a micro-simulation of foaming in the injection moulding process.<\/p>\n","protected":false},"featured_media":12432,"parent":0,"template":"","tags":[921,994],"research_fields":[813,817,1174],"class_list":["post-12443","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-injection-moulding","tag-simulation-en-2","research_fields-injection-moulding","research_fields-materials-technology","research_fields-simulation-en"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>TSG Mikro Sim - Multi-scale foam simulation | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Physically foamed thermoplastic injection moulded components have many advantages over compact parts. However, precise technical design using structural simulation is not possible, as effects such as cell deformation due to shear effects, coalescence and bubble collapse are not taken into account. This is where the DFG project comes in, investigating how these effects can be modelled and calculated using a micro-simulation of foaming in the injection moulding process.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/tsg-mikro-sim-multi-scale-foam-simulation\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"TSG Mikro Sim - Multi-scale foam simulation | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"Physically foamed thermoplastic injection moulded components have many advantages over compact parts. However, precise technical design using structural simulation is not possible, as effects such as cell deformation due to shear effects, coalescence and bubble collapse are not taken into account. 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