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PROcess Simulation of COMPression moulding – PROSICOMP

The transport sector and especially the automotive industry are facing significant challenges when it comes to reducing the CO2 emissions. To achieve the upcoming legislations a significant weight reduction of the vehicles is necessary. It is foreseen by the automotive industry that a weight reduction of over 100 kg for the body in white is required after the year 2020. The industry estimates that a weight reduction of about 50 kg is realistic using current metal technologies and to reach further than that, structural composites are a necessity. The relatively high cost of the composite material requires the manufacturing method to be efficient, automated to a high degree and with a very low amount of waste material. One manufacturing method that has high potential of fulfilling these requirements is compression moulding. For the method to be used for components in high volume car models the tools for simulating the process however need to improve in accuracy and maturity. The fast development cycles in the automotive industry (currently ~30 months, aiming towards 20 months) disqualifies the use of prototype tooling and successive tuning to optimize the manufacturing. Instead it must be possible to go directly to serial tooling and for doing this; accurate process simulation tools are essential. This project aims at developing such virtual tools and models through two industrial PhD-students. Virtual tools will be developed both for the conceptual phase where simple and rapid tools are sought after and for the manufacturing development phase where detailed tools are needed. The models and methods w ill be implemented at the industries in parallel to the PhD-work.

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