Topology optimization – Removing unnecessary materials

The plastic reinforcements and ribbing that are characteristic of hybrid components are not subjected to the same uniform level of stress in all areas. This means that areas subjected to a lower level of loading can be made thinner so as to save on material and minimize the weight of the component. In contrast, areas that have to cope with peak loads can be made thicker. Topology optimization is a simulation tool that is used to improve structures in precisely this way. This tool can identify the optimal ribbing and reinforcement structure for maximum component stiffness. The tool "virtually" removes material from areas of the part that are not subjected to loads. This provides information on where ribs and reinforcements should be positioned and on their required thicknesses. Consequently, with more or less the same amount of material and thus the same costs per part, the components are much stiffer and thus much more load-resistant as a result of the simulation.

Integrative simulation – calculating direction-dependent component properties

In the injection molding of glass-fiber-filled thermoplastics, the glass fibers added to reinforce the material assume different orientations during the mold filling process, depending on the component section and wall thickness. This exerts an influence on certain properties of the molded part, such as shrinkage, stiffness and strength, which may well cause problems at a later stage. Integrative simulation makes it possible to accurately describe the properties of the part and optimize it in terms of weight and peak loads. This type of simulation combines process simulation with structural analysis to enable the internal component properties resulting from the manufacturing process to be used in subsequent simulations. LANXESS has developed this simulation tool to the stage where it can be used to deliver very good results quickly, even for complex components such as highly integrated oil pans and front ends.