Simulation of materials, processes and applications

SGL Group has many years of experience in the development and simulation of production processes and applications in the field of carbon, graphite, ceramics, or composites. We find solutions for problems that arise during the production of these materials (process modeling), and provide solutions and information about the use of these materials in customer applications (application modeling). In addition, we calculate material properties based on the nature of the raw materials used in production (material modeling) and solve optimization problems.

Based on these activities, we offer extensive knowledge in the following areas:

Pressure vessel design

Background:

Difficulties arose with the manuel design of complex systems to meet requirements of the EU Pressure Equipment Directive (PED).

Method:

Calculation and evaluation of mechanical stresses by FEM was done based on AD-Merkblatt specifications.

Result:

Based on the simulation results, material specific design criteria were developed.

Construction of an extruder mold for ceramic masses

Background:

A certain extruder mouthpiece produced with a higher defect rate than others.

Method:

Based on the simulation of fluid dynamics (CFD) of the extrusion process, the mold design could be optimized.

Result:

A new extruder mold was produced on the basis of the simulation results, and the defect rate was significantly reduced.

Simulation of the viscosity of a ceramic mass during extrusion

Thermomechanical design of ceramic coated graphite components

Background:

Exposure to strong temperature changes affected the service life of a coated graphite component.

Method:

The design of the component was revised usig a thermomechanical model.

Result:

The model correctly predicts the areas with the greatest probability of failure, thus it enabled optimization of the component geometry and prolonged its useful life.

Temperature distribution (left) and stress distribution (right) in a ceramic coated graphite component during use

Optimization of an HCl synthesis plant

Background:

Quality improvement measures in the production of HCl gas were sought.

Method:

The gas flow and heat transfer were optimized by simulation of the fluid dynamics.

Result:

A newly developed burner design, with an optimized reaction zone, provides a higher product quality.

Plant for HCl synthesis and HCl absorption

Background:

A mechanically loaded component needs to be designed to have the highest possible stiffness with the lowest possible weight. The outer dimensions of the component are predetermined.

Method:

An optimization algorithm is used to remove material from the component where it does not contribute to the stiffness.

Result:

The specific stiffness of the component was doubled compared to a component with a solid design.

Topologically optimized cantilever made from Carboprint with bending stress distribution

Background:

Elaborate planning of:

  • Distribution of raw materials
  • Transport of semi-finished products
  • Utilization of equipment

Method:

The so-called „bin packing“ method is used for development and programming of optimizations.

Result:

Computer aided planning allows cost savings through reduced work, less time or a higher yield.

Visualization of mathematical optimization (in this case maximization)

Determination of the reaction kinetics during thermomechanical purification

Background:

Optimization of process management during thermomechanical purification of graphite was undertaken.

Method:

The reaction kinetics were determined in laboratory experiments and transferred into a thermomechanical model of the production process.

Result:

Thanks to optimized temperature and process gas control, the environmental impact was reduced.

Visualization of the procedure to determine the reaction kinetics by means of laboratory tests and model supported evaluation

 

The targeted use of modeling provides many advantages:

  • Reduction of development and production costs
  • Acceleration of the development of new products and services
  • Optimal use of existing plants and optimized design of new plants
  • Efficient solutions through in-depth investigation of physical and economic contexts

Through in-house measuring equipment and pilot plants, we are able to determine ourselves the material properties required for the modeling. In addition, since we can validate our simulation results with experimental tests, we are able to offer complete solutions based on both simulation and testing.

Outline of the modeling process from the customer request to the presentation of the solution

                                                                                                                                                                                            With our experience and our interdisciplinary skills, as well as our understanding of industrial and business processes, we will be glad to support your needs.

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