Integrated simulation of the process chain composite extrusion–milling–welding for lightweight frame structures

Abstract

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.

Numerical Investigation into the Effect of Different Parameters on the Geometrical Precision in the Laser-Based Powder Bed Fusion Process Chain

“…Afazov [40] integrated different software packages to model the manufacturing chain of aero components. Finally, Zaeh et al [41] modelled a process chain for a frame consisting of a box profile attached to a tube. They include the forming of both elements, milling into shape and the joining process, which in this case is welding.…”