The increased requirements of plastic parts more and more lead to higher importance of acoustic component properties. To optimise these properties in practice often time consuming and complex component tests are carried out. Thus the IKV is dealing with the development of methods to optimise the acoustic behaviour virtually. In this context a plastics-oriented, on part independently measured material parameters based FEA simulation method is improved that allows a realistic prediction of the structure-borne sound behaviour of any components. (Read more in the PDF)

For a safe design of plastic parts it is necessary to know the long-term properties of the material. During its service life a plastic part can be influenced by different environmental factors. The mechanical properties e. g. can change drastically if the part gets in contact with an aqueous medium. The Environmental Stress Cracking (ESC) is one of the most important causes for part failure. (Read more here in the PDF)

When it comes to part design the competence of IKV lies in the integral examination of the whole plastic application. Hereby the existing loads, the environmental conditions and the production process are taken into account for the simulation and design process. Based on this integral view IKV has developed plastics-specificmaterial models and simulation chains which enable anoutstanding simulation accuracy and thus a highly precise part design for many different applications. Thereby the developed methods enclose material data determination as well as the calibration of linear and non-linear models.

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The competence of IKV regarding the description and the simulation of thermoplastics under impact loading is the ability to take various essential influencing factors on the  material behaviour into account. Therefore material models are developed which can engage the plastic deformation as well as the strain rate dependency of the mechanical material behaviour up to the point of material failure. Since the availability of material data for such material models is very limited, IKV has developed methods and software tools for the determination and the pre-processing of material data. These are based on experimental data from high speed tensile tests. By means of a computer-aided optimisation process material cards are automatically generated in the format needed for the desired FEA program. (Read more in the PDF)

Short glass fibre reinforced plastics increasingly are used for dynamic-mechanically loaded structural components. To lay out these components against dynamic cyclic loading either timeand cost-intensive Woehler curves for prototype parts are determined or insecurities for dimensioning are balanced by huge safety factors for lack of alternatives. This leads to high development costs respectively to oversizing of the part. Hence the IKV is working on the development of simulative methods for dimensioning the life time of short glass fibre reinforced plastic components. (Read more in this PDF)

One of the main strengths of the Institute of Plastics Processing is the integrated consideration of the development process of plastic parts, from the idea to the finished product. Goal of our research activities is a computer-based design process, which allows the virtual analysis and optimisation of plastic parts in early design stages. In this area of the design process the working group “material selection / plastic tailored part design” aims to transfer research content into industrial practice. The Institute of Plastics Processing offers a wide variety of activities for the computer-based design process from the part concept to the material selection to the process simulation and dimensioning of the part against external forces by using finite element analysis. Our material know-how supports the computer-based design and leads to optimal functional plastic parts. (Read more in the PDF)

The material behaviour of elastomers is very complex and shows significant non-linearities. Only the use of modern simulation methods guarantees an efficient dimensioning of rubber parts. The strength of the IKV are both the determination of realistic material parameters and the numerical dimensioning process using the Finite-Element-Analysis (FEA). By developing own material models for the description of the material behaviour of elastomers the accuracy of simulations for a precise part design process has been increased. (Read more in the PDF)

A great strength of the IKV is material testing of thermoplastics and elastomers regarding the determination of material parameters for precise FE-structural-analyses or other applications like the characterisation of the chemical resistance of plastics. Futhermore, a comprehensive part testing equipment is available. Resulting from high research requirements, a qualified and motivated team accomplishes both the determination of mechanical material parameters as well as comprehensive part testings. The IKV, as a reliable service provider, realises these analyses affordably, fast and competently. (Read more in the PDF)

In recent years laser welding has been established within industrial practice due to its process specific advantages. Since the middle of the nineties of the last century the IKV has been researching on the field of this innovative joining technology. Both material related topics and new process developments have been investigated, in order to expand the spectrum of application of laser welding in plastics processing.  (Read more in the PDF)

In order to realise functional systems in plastics processing it is often necessary to use welding processes to join several plastic parts. For that purpose there are a number of different welding processes available. For a successful application in industrial production lines an accurate knowledge of the specific welding processes is essential. The IKV has been researching on the field of welding technologies for several decades. For that reason the IKV offers its experiences to support industrial partners in welding specific problems.

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Plasma technology for surface functionalisation has been in the focus of research for more than two decades at the Institute of Plastics Processing at RWTH Aachen University. The central aspect of our work is to generate novel surface properties in order to compensate restrictive features such as e.g. inadequate high gas permeability. The process and plant technology for plasma-based coating of plastics surfaces developed at our Institute has been fundamentally explored within numerous publicly funded research projects. The technology is being consistently improved regarding industrial implementation. (Read more in the PDF)

Plasma technology for surface functionalisation has been a field of research at the Institute of Plastics Processing for more than two decades. The main focus hereby is to modify plastic sur-faces in order to generate novel surface properties, being inde-pendent from the bulk material.

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