Simulation of the pultrusion process

Simulation is a versatile and interdisciplinary field. In addition to classic structural calculations, it now also covers key issues in process analysis. In the field of pultrusion in particular, there has been a strong reliance on empirical knowledge and trial-and-error approaches. However, increasing efficiency requirements and demographic challenges are making a rethink necessary.

From a structural perspective, the use of numerical simulations (e.g., FEM) is no longer uncommon in the composites sector. Nevertheless, it requires special consideration due to the specific, mostly anisotropic laminate structures. At the same time, the demand for reliable process simulations is growing, particularly in light of increasing economic efficiency requirements and shorter development cycles. In the pultrusion process, these can be roughly divided into three areas:

• Fibre feeding and draping
• Impregnation
• Curing and warping

An in-depth understanding of these process steps, as enabled by simulations, contributes significantly to designing the pultrusion process more efficiently while also better understanding and specifically addressing existing problems.

At Fraunhofer IWU, we act as your development partner across all of these aspects. Our long-standing expertise, combined with insights from public research projects and the latest research results, is continuously integrated into our developments – for example, in the design of injection boxes or the development of sophisticated tooling concepts for the targeted compensation of distortion-induced shrinkage effects.