Modelling and Idealisation in Manufacturing Simulation

Manufacturing processes are complex multi-physical processes, which are used for producing components with defined geometries and properties. Hence, the complexity of manufacturing processes results from the interplay of various domains of physics, such as mechanics, dynamics, and thermodynamics. Simulation tools are playing an increasingly important role in this context. They have become indispensable for the planning and optimization of manufacturing processes. The first step in simulating these processes is modeling and idealization. This first step is examined in this module and divided into four parts. 

Part I of the module focuses on manufacturing processes such as forming and joining. Practical examples illustrate the implications for the validity of finite element simulations with regard to the choice of models and numerical solutions. 
Part II deals with the mechanisms of heat transfer, such as thermal conduction, heat transfer, and thermal radiation. Analytical and empirical solution approaches are presented for standard situations. 
Part III addresses fundamental phenomena of nonlinear material behavior as well as the determination of associated model parameters.  
In Part IV of the module, the computer-aided modeling of multi-body systems based on the basic elements of rigid bodies, nonlinear springs, and viscous dampers is introduced. Numerical examples will be implemented from scratch.

Learning objectives: upon successful completion of the module, students will be able to independently make and critically evaluate model assumptions in the context of manufacturing process simulations. Furthermore, students will be able to analyze and solve technically relevant heat transfer problems and discrete dynamic systems, classify mechanical material behavior, and determine model parameters.