Modelling & simulation

Better predicting the behaviour of processes and structures to accelerate development

At IRT Jules Verne, numerical simulation is used to develop and optimise manufacturing processes. It provides objective criteria to guide decision-making. In particular, it enables the comparison of different technical solutions and the identification of influential parameters.

In the case of manufacturing processes, IRT Jules Verne studies both the phenomena involved in material transformation and the technologies required to implement them, through the modelling of tooling and manufacturing cells. The Institute thus contributes to assessing feasibility, defining the operating window and predicting achievable performance in terms of material integrity, geometric distortions and residual stresses. The work carried out by the team addresses three major challenges:

• Improving industrial performance by reducing development times and costs, optimising operating windows and controlling energy consumption.
• Strengthening process control by understanding physical phenomena, designing more robust processes and tooling, taking into account variations in materials and processes, and anticipating their impact on in-service performance.
• Developing practical digital tools: prediction and decision-support tools to aid in the design, optimisation and control of processes.

Our expertise and technological building blocks in modelling and simulation

IRT Jules Verne’s roadmap for modelling and simulation covers the entire digital chain. It combines the modelling of material behaviour, process simulation, the modelling of production facilities and the development of decision-support tools.

Our core expertise in Modelling and Simulation

Simulation and optimisation of composite processes

Working closely with the Composite Processes and Materials team, the Modelling and Simulation team studies the processes involved in the fabrication of thermosetting and thermoplastic materials. Simulation is used during the development and optimisation phases of composite processes, particularly for liquid-phase processes (RTM, infusion), forming and consolidation processes (stamping, thermocompression, autoclave), hybrid processes (overmoulding) and assembly by welding.

The aim is to be able to anticipate the filling, firing, consolidation and demoulding stages of the components by predicting as accurately as possible the flow patterns, temperatures and deformations generated, as well as potential defects (dry spots, porosity, wrinkling, etc.). Digital tools thus enable the feasibility of the process to be assessed, its operating window to be defined and the manufacturing parameters to be optimised.

The accuracy of the simulations depends largely on the ability to model the behaviour of the material during the manufacturing stages, as well as on taking into account the actual behaviour of the tooling and the environment.

Simulation and optimisation of metallic processes

Working closely with the Metallic Materials Processes team, the Modelling and Simulation team models welding, additive manufacturing and cold or hot forming processes.

The research covers both the effects of heat input (weld bead dimensions, phase transformations, residual stresses, geometric deformations) and the generation of heat itself, as well as the physical phenomena in the heat-affected zone (arc plasma, arc-bath interactions, keyhole). Simulation is also used to support the design of welding tools (laser heads, inerting tools, pre- or post-heating modules).

Additive manufacturing

This extensive expertise in welding modelling is extended to the simulation of additive manufacturing processes. The team’s work focuses in particular on arc and laser DED (Directed Energy Deposition) processes. The main objectives are to control thermal conditions throughout the manufacturing range to ensure material integrity and geometric conformity, as well as to optimise manufacturing strategies for productivity.

Forming

The simulation of forming processes focuses on improving the predictive capabilities of simulations (particularly in terms of geometric control) and optimising tool life. The IRT addresses standard forming processes as well as niche processes such as flexforming and SPF.

Digital twin of the process

Beyond understanding and developing processes, IRT Jules Verne is developing digital twin approaches to support process control.

These virtual replicas enable the behaviour of a process to be faithfully reproduced, allowing changes to be anticipated and deviations to be detected. The digital models that form the computational core of the twin combine a representation of physical phenomena with data from the actual process, ensuring realistic simulations tailored to each industrial context.

To meet the requirements for speed of execution and accuracy, the Modelling and Simulation team – in collaboration with the Monitoring, Inspection and Control team – utilises advanced modelling methods, notably those involving artificial intelligence. These approaches adhere to the physical laws governing the process whilst remaining usable in real time – essential assets for process control and reliable decision-making.

Assembly and tolerancing

The Modelling & Simulation team has developed in-depth expertise in tolerance-related issues, which are key to assembly sequences and, consequently, to the optimisation of production rates.

The team develops virtual metrology tools to compare the results of its simulations (part geometry) with the specified tolerances.

The work also aims to account for uncertainties (material, process parameters, environment) in order to determine, via simulation, the manufacturing tolerances of a part or to estimate process non-conformance rates. In this context, the team seeks to prioritise parameters and develop frugal uncertainty propagation methods (large number of process parameters, very low compliance rates).

Finally, in the case of assemblies comprising very large parts or sheet metal components, the IRT Jules Verne addresses the issue of the flexibility of assembled parts.

Thermal management of processes

Thermal management is a key challenge in the control of composite and metal-based processes.

Using modelling, the team supports process development: defining and controlling heating and cooling cycles and designing moulds (thermal and energy performance). The use of simulation ensures thermal uniformity across moulding surfaces, controls thermal gradients, assesses tool expansion, and anticipates and compensates for geometric distortions in parts.

Beyond process control to guarantee the quality of the parts produced, the team seeks to improve industrial performance:

• Optimising the energy consumption of processes (minimising losses, recovery, utilisation)
• Reducing tooling costs by extending their service life.