Simulation Tools in Production Planning

11M0630

Master

German

5.0

only summer term

1 semester

The ever shorter time-to-market and increasing quality requirements for new products can only be achieved by synchronizing product and production development to the greatest possible extent with data-integrated software tools. On the production side, this ensures reliable target costs and quality, steep production start-up curves and optimum plant operation.

The understanding and practical application of modern simulation tools with a focus on production processes and production sequences is fundamental to this. On the one hand, manufacturing processes such as forming, welding and injection molding must be considered. On the other hand, the investigation of production processes such as painting, the use of industrial robots, manual assembly scenarios and material flows is important. These teaching contents are framed by a fundamental transfer of knowledge and methods for the targeted and efficient implementation of simulation investigations and stimulation studies.

Excursions are carried out as required to accompany the course.

1. basics -> production-related simulation techniques and tools, implementation of simulation studies, simulation tools in the digital factory

Block A: Simulation of manufacturing processes:
2. forming simulation -> strategies, non-linear finite element method, material properties, contact conditions, process sequence

3. welding simulation -> Radaj triangle, heat conduction models, distortion, residual stresses, simulation sequence

4. plastic injection molding simulation -> basics, analysis options, meshing methods, simulation procedure

Block B: Simulation of complex production processes:
5. painting simulation -> particle flow vs. coating process, process and workpiece modeling, presentation of results

6. robot simulation -> overview of simulation tools, realistic robot simulation, collision-avoiding path planning, offline path/program creation

7. human simulation and ergonomics analyses -> human model, biomechanics, motion definition, analysis methods

8. event-oriented simulation -> areas of application, mode of operation, data preparation, evaluation of results

The simulation tools used in the practical simulation exercises are Autoform, Simufact, Moldflow, Process Simulate and Plant Simulation.

The total workload for the module is 150 hours (see also "ECTS credit points and grading").

• Written examination or
• oral exam

• Field work / Experimental work

After completing this module, students will differentiate between the common production-related simulation tools and describe their benefits in the production environment. They explain how simulation programs work and identify expected accuracies and inaccuracies when carrying out simulation studies.

After completing the module, students apply selected simulation tools in a targeted manner and independently carry out simulation studies on production-relevant tasks. They critically reflect on the results that can be derived from simulation studies and organize the implementation of these in the production environment in the sense of continuous improvement management.

After completing the module, students select relevant data (including mass data) for simulation studies and analyze them with a view to implementing suitable simulation models. They prove the correctness of the simulation models created by means of verification and validation on the basis of scientific findings from specialist literature and case studies. In this context, students also develop research questions for the further development of simulation tools and the appropriate application methodology.

• Rokossa, Dirk

• Rokossa, Dirk
• Sachnik, Peter