COMPUTER AIDED ENGINEERING Integrated simulation of the process chain composite extrusion–milling–welding for lightweight frame structures Michael F. Zaeh • A. Erman Tekkaya • Dirk Biermann • Andreas Zabel • Mirko Langhorst • Alexander Schober • Thomas Kloppenborg • Markus Steiner • Eduard Ungemach Received: 19 August 2009 / Accepted: 30 October 2009 / Published online: 14 November 2009 Ó German Academic Society for Production Engineering (WGP) 2009 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. Keywords Simulation  Process chain  Lightweight frame structures  Software interfaces  Composite material 1 General introduction The Transregional Collaborative Research Centre 10 (SFB/ TR 10) ‘‘Integration of forming, cutting and joining for the flexible production of lightweight frame structures’’ is fun- ded by the German Research Foundation (DFG) at the TU Dortmund, the Universitaet Karlsruhe and the Technische Universitaet Muenchen. A major objective is the investi- gation of the integrated process chain including the processes of extrusion, cutting and joining in reality as well as in simulation. In the field of simulation the subprojects B1 (composite extrusion simulation), B2 (simulation of the five- axis milling process), B3 (mechanical simulation of the machining process), B4 (welding simulation) and C7 (sim- ulation of the process chain) are researching the different manufacturing processes and their influences regarding the process chain. Within the TR 10 the use of simulation methods is on the one hand to gain knowledge of the applied processes and on the other hand to optimize them regarding particular variables. Thus, optimized process parameters can be computed to minimize structural workpiece reactions such as stresses und strains. In particular, these variables are of special interest because the investigated structures within the TR 10 are transportation related and thus, a high safety factor is demanded. Hence, information about critical stress situations in the structure is in the focus of interest. A challenge for the real process chain is the machining of steel reinforced aluminium. This novel material is dif- ficult to cut and join because of the different material properties of steel and aluminium. Designing lightweight structures requires a detailed knowledge of the final part properties, especially the dis- tortions and the residual stresses, which are a result of the entire manufacturing history. By using simulation methods it is possible to determine the structural effects of every single process step on the work piece and at last of the whole manufacturing chain. In contrast to reality, a challenge arises in the simulation when actually chaining the different manufacturing steps together. Due to the different data formats of the various software tools that are used in the subprojects interfaces between these systems are necessary to realise an integrated virtual process chain (Fig. 1). In addition, an alternative method without using inter- faces is also investigated in this paper. Namely, the entire M. F. Zaeh  M. Langhorst (&)  A. Schober Technische Universita ¨t Mu ¨nchen, Munich, Germany e-mail: mirko.langhorst@iwb.tum.de A. E. Tekkaya  D. Biermann  A. Zabel  T. Kloppenborg  M. Steiner  E. Ungemach TU Dortmund, Dortmund, Germany 123 Prod. Eng. Res. Devel. (2009) 3:441–451 DOI 10.1007/s11740-009-0190-0