Design Guidelines to Balance the Flow Distribution in Complex Profile Extrusion Dies

Rajkumar, Ananth; Ferrás, Luís Jorge Lima; Fernandes, Célio; Carneiro, O. S.; Becker, Mirco; Nóbrega, J. M.

doi:10.3139/217.3272

Cited by 13 publications

(13 citation statements)

References 22 publications

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“…At the solid die wall, the no-slip (tangential velocity is zero) and no-penetration (normal velocity is zero) conditions are imposed for velocity, zero-gradient pressure, and a fixed value temperature. At the free-surface, the kinematic condition, Equation (8), and the dynamic condition, Equations ( 10) and (11), are imposed for pressure and velocity, along with natural convection, Equation (12), for temperature. Finally, the outflow plane is taken sufficiently far downstream of the die exit so that the flow is uniform.…”

Section: Problem Domain and Meshesmentioning

confidence: 99%

“…The polymer production process is mainly non-isothermal in nature, including heat transfer phenomena such as heating and cooling, e.g., in the injection molding [3,4] or extrusion [5][6][7][8] processes. Since the flow properties are strongly dependent on rheology and temperature, it is of great interest to understand and predict this type of heat transfer phenomenon.…”

Section: Introductionmentioning

confidence: 99%

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Non-Isothermal Free-Surface Viscous Flow of Polymer Melts in Pipe Extrusion Using an Open-Source Interface Tracking Finite Volume Method

2021

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Polymer extrudate swelling is a rheological phenomenon that occurs after polymer melt flow emerges at the die exit of extrusion equipment due to molecular stress relaxations and flow redistributions. Specifically, with the growing demand for large scale and high productivity, polymer pipes have recently been produced by extrusion. This study reports the development of a new incompressible non-isothermal finite volume method, based on the Arbitrary Lagrangian–Eulerian (ALE) formulation, to compute the viscous flow of polymer melts obeying the Herschel–Bulkley constitutive equation. The Papanastasiou-regularized version of the constitutive equation is employed. The influence of the temperature on the rheological behavior of the material is controlled by the Williams–Landel–Ferry (WLF) function. The new method is validated by comparing the extrudate swell ratio obtained for Bingham and Herschel–Bulkley flows (shear-thinning and shear-thickening) with reference data found in the scientific literature. Additionally, the essential flow characteristics including yield-stress, inertia and non-isothermal effects were investigated.

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Section: Problem Domain and Meshesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Non-Isothermal Free-Surface Viscous Flow of Polymer Melts in Pipe Extrusion Using an Open-Source Interface Tracking Finite Volume Method

2021

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“…Ettinger gives an overview of work regarding shape optimization [13]. More recent research can be found in [24,31,22]. We note that all of this work is focused on shape optimization of the flow channel.…”

Section: Local Heating Of Extrudersmentioning

confidence: 99%

Optimizing Micro-Tiles in Micro-Structures as a Design Paradigm

Antolín

Buffa

Cohen

et al. 2019

Computer-Aided Design

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In recent years, new methods have been developed to synthesize complex porous and micro-structured geometry in a variety of ways. In this work, we take these approaches one step further and present these methods as an efficacious design paradigm. Specifically, complex micro-structure geometry can be synthesized while optimizing certain properties such as maximal heat exchange in heat exchangers, or minimal weight under stress specifications.By being able to adjust the geometry, the topology and/or the material properties of individual tiles in the microstructure, possibly in a gradual way, a porous object can be synthesized that is optimal with respect to the design specifications. As part of this work, we exemplify this paradigm on a variety of diverse applications.

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“…In the past, a number of design methods for polymer profile extrusion dies have been reported [4], which are primarily classified in two kinds of approaches for the extrusion die design [5] [6].…”

Section: Introductionmentioning

confidence: 99%

“…Rajkumar et al [5] adopted a novel method to balance the flow distribution in the extrusion die, and the cross-section geometry was divided into L and T shaped profiles. Yilmaz et al [7] proposed objective functions based on uniformity of velocity distribution at the die exit and adopted the Simulated Annealing-Kriging Meta-Algorithm for the optimization of extrusion die geometry.…”

Section: Introductionmentioning

confidence: 99%

Optimized Design Method for Profile Extrusion Die Based on NURBS Modeling

Zhang

Huang

et al. 2019

Fibers Polym

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For optimization design of polymer extrusion dies, dimensional accuracy is critical to product quality of the extrudate. The extrusion dies used to be a regular geometrical profile, which is mostly composed by a straight line. Traditional optimization methods for extrusion die design used to have poor controllability when dealing with a curved profile. In this paper, the response surface optimization method is used to find out an optimal solution of the design of the extrusion die. Firstly, the Latin Hypercube Sampling method is used to generate the experiment samples for the design of experiments. Secondly, ANSYS Polyflow software is adopted to execute the computational fluid dynamics analysis. Thirdly, the Kriging method is used to generate the response surface. Finally, nonlinear programming by using Quadratic-Lagrangian algorithm is applied to find out the optimal solution. It is worth noting that Non-uniform Rational B-Splines (NURBS) modeling is used to optimize flow channel of an extrusion die in order to obtain a qualified extrudate. Thus, design variables for the optimization involve control points of the NURBS curve of the inlet cross-section. Meanwhile, two new objective functions, including minimization of point displacement and minimization of dimensional tolerance are proposed in the optimization process. Compared with existing objective functions of flow balancing and homogeneous die swell, the new objective functions of minimization of point displacement and minimization of dimensional tolerance have significant advantages of strong adaptability, more precise shape of the extrudate and fast convergence, which significantly improve efficiency of the optimization design and thus lower manufacturing costs of the extrusion die.

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Design Guidelines to Balance the Flow Distribution in Complex Profile Extrusion Dies

Cited by 13 publications

References 22 publications

Non-Isothermal Free-Surface Viscous Flow of Polymer Melts in Pipe Extrusion Using an Open-Source Interface Tracking Finite Volume Method

Non-Isothermal Free-Surface Viscous Flow of Polymer Melts in Pipe Extrusion Using an Open-Source Interface Tracking Finite Volume Method

Optimizing Micro-Tiles in Micro-Structures as a Design Paradigm

Optimized Design Method for Profile Extrusion Die Based on NURBS Modeling

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