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Transcript of Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic...
![Page 1: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/1.jpg)
Extrusion Simulation and Optimization of Profile Die Design
03-25-2003
Advisor
Prof. Milivoje Kostic
By
Srinivasa Rao Vaddiraju
![Page 2: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/2.jpg)
Extrusion describes the process by which a polymer melt is pushed across a metal die, which continuously shapes the melt into the desired form.
Gear pump
A Schematic of Profile Extrusion Line at FNAL
IntroductionD
ryer
Cutter
Feeding
Hopper
Extruder
Die
Calibrator
Cooling
Measurement
Haul-off
Polymer pellets Dopants
Breaker plate
![Page 3: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/3.jpg)
Quality factorsExtrudate swell
Draw down CoolingInsufficient mixing in the extruder Uneven die body temperatures and raw material variations Non-uniform viscosity in the die
Non-uniform swellingNon-uniform draw down
rearrangement of the velocity profile as the polymer leaves the die
![Page 4: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/4.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 5: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/5.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion
Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 6: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/6.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion
Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 7: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/7.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.
Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 8: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/8.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.
Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 9: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/9.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.
Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.Prepare the complete design of dies, including blue prints.
Objectives
![Page 10: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/10.jpg)
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.
Prepare the complete design of dies, including blue prints.
Objectives
![Page 11: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/11.jpg)
Design Methodology
•Using Finite Element based CFD code Polyflow
•Using the method of Inverse Extrusion
•To fully understand the extrusion processes and the influence of various parameters on the quality of the final product.
•Integrate the simulation results and the experimental data to obtain more precise extrudate shape.
![Page 12: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/12.jpg)
Literature Review
The text book “Dynamics of Polymeric Liquids” by R.B.Bird gives a detailed overview of non-Newtonian fluid dynamics, which is important to understand the flow of polymers.
The text book “Extrusion Dies” by Walter Michaeli gives an extensive representation of extrusion processes and guidelines for the design of dies.
The text book “Plastics Extrusion Technology Handbook” by Levis gives a clear representation of the rheology of materials and the technology of extrusion processes.
Woei-Shyong Lee and Sherry Hsueh-Yu Ho have investigated the die swell behavior of a polymer melt using finite element method and simulated flow of Newtonian fluid and designed a profile extrusion die with a geometry of a quarter ring profile
Louis G. Reifschneider has designed a coat hanger extrusion die using a parametric based three-dimensional polymer flow simulation algorithm, where the shape of the manifold and land are modified to minimize the velocity variation across the die exit.
W.A. Gifford has demonstrated through an actual example how the efficient use of 3-D CFD algorithms and automatic finite element mesh generators can be used to eliminate much of the “cut and try” from profile die design.
![Page 13: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/13.jpg)
Governing Equations
Where, P is the pressure,
τ is the extra stress tensor,
v is the velocity.
Continuity Equation
Momentum Equation
0
zyx vz
vy
vx
zyxx
P xzxyxx
zyxy
P yzyyyx
zyxz
P zzzyzx
![Page 14: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/14.jpg)
disscondconvacc EEEE
t
TCE vacc
z
Tv
y
Tv
x
TvCE zyxvconv
z
Tk
zy
Tk
yx
Tk
xEcond
y
v
z
v
x
v
z
v
x
v
y
v
z
v
y
v
x
vE
zyyz
zxxz
yxxy
zzz
yyy
xxxdiss
Energy Equation
Where, Cv is the specific heat capacity of the material,
T is the temperature,
ρ is the density,
k is the thermal conductivity.
the accumulation term,
the convection term,
the conduction term,
the dissipation term,
![Page 15: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/15.jpg)
Die Design
The ‘art of die design’ is to predict ‘properly irregular’ die shape (with minimum number of trials) which will allow melt flow to reshape and solidify into desired (regular) extrudate profile.
The correct geometry of the die cannot be completely determined from engineering calculations.
Numerical methods
![Page 16: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/16.jpg)
POLYFLOW
Finite-element CFD code
Predict three-dimensional free surfaces
Inverse extrusion capability
Strong non-linearities
Evolution procedure
![Page 17: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/17.jpg)
Flowchart for numerical simulation using Polyflow
1. Draw the geometry in Pro-E (or) other CAD software and export to GAMBIT
2. Draw the geometry in GAMBIT (or) import from other CAD software and mesh it.
3. Specify Polymer properties in Polydata
4. Specify boundary conditions in Polydata
8.Is the solution converged?
Stop
5. Specify remeshing technique and solver method in Polydata
Yes
No
6. Specify the evolution parameters in Polydata
7. Polyflow solves the conservation equations using the specified data and boundary conditions
Modify the evolution
parameters
Change the remeshing techniques and/or
solver methods
Modify the mesh
![Page 18: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/18.jpg)
General Assumptions
0t
and incompressible 0 v
Body forces and Inertia effects are negligible in comparison with viscous and pressure forces.
The flow is steady
Specific heat at constant pressure, Cp, and thermal conductivity, k, are constant
![Page 19: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/19.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.
All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 20: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/20.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline
velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.
All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 21: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/21.jpg)
Boundary Conditions
0. nv
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.
All domains: Viscous dissipation was neglected for all flow conditions (after verification).
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
![Page 22: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/22.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.
All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 23: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/23.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and
convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 24: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/24.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential
Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 25: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/25.jpg)
Boundary Conditions
0. nv
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0),
and convection heat transfer from the free surface to surrounding room-temperature air.
Kinematic balance equation
on δΩfree
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference
pressure) and normal heat flux qn =0.
All domains: Viscous dissipation was neglected for all flow conditions (after verification).
![Page 26: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/26.jpg)
Material Data
Zero shear rate viscosity, η0 = 36,580 Pa-s
Infinite shear rate viscosity, η∞ = 0 Pa-s
Natural time, λ = 0.902
Transition Parameter, a = 0.585
Exponent, n = 0.267
Density, ρ = 1040 Kg/m3
Specific Heat, cp = 1200 J/Kg-K
Thermal Conductivity, k = 0.12307 W/m-K
Coefficient of thermal expansion, β = 0.5e-5 m/m-K
a
na
1
0 1
Styron 663, mixed with Scintillator dopants
Carreau-Yasuda Law for viscosity data:Measured by, Datapoint Labs
![Page 27: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/27.jpg)
Styron viscosity data, with and without Scintillator dopants
Shear Rate (1/s)
Vis
cosi
ty (
Pa-
s)
200 0C180 0C
220 0C
η – Styron 663
ηd– Doped Styron 663
106
105
104
103
102
10-210-1 100 101 102 103
![Page 28: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/28.jpg)
Profiles
•Rectangular profile die with one hole
•Rectangular profile die with ten holes
![Page 29: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/29.jpg)
Rectangular profile die with one hole
2.0
1.00.11
ALL DIMENSIONS ARE IN CM
Required extrudate is a rectangular cross section of 1 cm 2 cm with a circular hole of 1.1 mm diameter at its center
![Page 30: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/30.jpg)
Percentage Differences P1(0,y) P5(x,0) P2(0,y) P4(x,0) P3(x) P3(y) Reference 0 0 0 0 0 0 Inertia terms not included -0.007% -0.001% -0.002% -0.001% -0.001% 0.002% Exponent in Carreau - 0.252 0.003% 0.001% 0.000% 0.000% 0.000% 0.000% Yasuda model, n 0.28271 1.495% -1.765% 0.646% 0.380% 0.465% 0.358% 0.3522 3.692% -4.583% 1.619% 0.979% 1.138% 0.864% 0.453 8.439% -11.776% 3.935% 2.521% 2.686% 1.995% 0.5286 11.354% -17.410% 5.718% 3.806% 3.876% 2.843% Zero shear 1.20E+05 0.007% 0.002% 0.000% 0.000% 0.000% -0.001%
rate viscosity, 0 (Pa-s) 1.34E+05 0.006% 0.002% 0.000% 0.000% 0.000% -0.001% 2.00E+05 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 2.40E+05 0.001% 0.002% -0.001% -0.001% 0.000% 0.001% 2.80E+05 0.000% 0.002% -0.001% -0.001% -0.001% 0.001% Flow rate (m3/s) 1.54E-05 0.640% 0.017% 0.232% 0.190% 0.245% 0.095% 2.15E-05 0.207% 0.014% 0.073% 0.060% 0.079% 0.030% 2.58E-05 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 3.04E-05 -0.189% -0.010% -0.069% -0.058% -0.074% -0.029% 3.61E-05 -0.352% -0.016% -0.128% -0.105% -0.136% -0.054% Transition 2 -2.757% 0.104% -1.025% -0.701% -0.932% -0.406% Parameter, a 0.5 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% Time constant, 2.31685 0.914% 0.020% 0.329% 0.269% 0.346% 0.133% 4.6337 0.000% 0.000% 0.000% 0.000% 0.000% 0.000% 7.53 -0.507% -0.030% -0.182% -0.148% -0.193% -0.075% 9.2674 -0.693% -0.042% -0.249% -0.203% -0.262% -0.102% Inverse Extrusion -0.18% 1.82% 0.17% 0.04% 0.3% 0.61%
Sensitivity analysis of die swell and inverse extrusion capabilities of Polyflow
P1 (0,y)
P2 (0,y)
P3 (x,y)
P4 (x,0)
P5 (x,0)
![Page 31: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/31.jpg)
Full domain of the extrusion die
Melt flow
direction
![Page 32: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/32.jpg)
Section 1
Section 2
Section 3
Die lip
Melt flow
direction
Half domain of the extrusion die
![Page 33: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/33.jpg)
Simulation domain with boundary conditions
1. Inlet (Fully Developed Flow)
2. Wall (Vn = 0, Vs = 0)
3. Symmetry (Vn = 0, Fs = 0)
4. Free Surface (Fs = 0, Fn = 0, V.n = 0)
5. Outlet (Fn = 0, Vs = 0)
![Page 34: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/34.jpg)
Finite element 3-D domain and die-lip mesh
Melt flow direction
Die Lip
30,872 elements
Skewness < 0.33
![Page 35: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/35.jpg)
19 hours and 36 minutes of CPU time
Windows XP
2.52 GHz Processor
1 GB RAM
![Page 36: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/36.jpg)
Die lip
Melt flow
direction
Contours of static pressure
![Page 37: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/37.jpg)
Die lip
Melt flow
direction
Contours of velocity magnitude at different iso-surfaces
![Page 38: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/38.jpg)
Melt flow
direction
Die lip
Contours of temperature distribution
![Page 39: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/39.jpg)
Contours of shear rate
Melt flow
direction
Die lip
![Page 40: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/40.jpg)
Existing die, corresponding simulation and new improved-die profiles
0
1
2
3
4
5
6
7
0 10X (mm)
Y (
mm
)
New Die (Simulated)Existing Die
Desired ExtrudateExisting-Die Extrudate
(Simulated)
![Page 41: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/41.jpg)
Exploded view of the extrusion die
![Page 42: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/42.jpg)
2 D-View of the extrusion die
Melt flow direction
![Page 43: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/43.jpg)
Blue prints
Preland Dieland
Pin
![Page 44: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/44.jpg)
Rectangular profile die with ten holes
10.00.5
0.11
ALL DIMENSIONS ARE IN CM
Required extrudate is a rectangular cross section of 0.5 cm 10 cm with ten equally spaced centerline circular holes
of 1.1 mm diameter.
![Page 45: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/45.jpg)
Full domain of the extrusion die
Melt flow
direction
![Page 46: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/46.jpg)
Half domain of the extrusion die
Melt Pump Adapter,
Adapter 1 and Adapter 2
Spider
Die land
Melt flow
direction
Die lip
Free Surface
![Page 47: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/47.jpg)
1
2
3
4
5
1. Inlet (Fully Developed Flow)
2. Wall (Vn = 0, Vs = 0)
3. Symmetry (Vn = 0, Fs = 0)
4. Free Surface (Fs = 0, Fn = 0, V.n = 0)
5. Outlet (Fn = 0, Vs = 0)
Melt flow
direction
Simulation domain with boundary conditions
![Page 48: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/48.jpg)
Finite element 3-D domain and half of extrudate profile mesh
Melt flow
direction
19,479 elements
Skewness < 0.5
![Page 49: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/49.jpg)
Half domain of the extrusion die (without free surface) and division
of outlet into 10 areas
d0
d1
d2
Melt flow
direction
out1out2out3out4out5out6out7out8out9out10
![Page 50: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/50.jpg)
Percentage of Mass flow rate in different exit segments
0.00% 5.00% 10.00%
Out1
Out2
Out3
Out4
Out5
Out6
Out7
Out8
Out9
Out10
Out
let
% of mass flow rate
Case 8
Case 7
Case 6
Case 5
Case 4
Case 3
Case 2
Case 1
![Page 51: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/51.jpg)
One hour of CPU time
Windows XP
2.52 GHz Processor
1 GB RAM
![Page 52: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/52.jpg)
Contours of Static pressure
Melt flow
direction
Die lip
![Page 53: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/53.jpg)
Contours of Velocity magnitude at different iso-surfaces and at centerline of exit
Melt flow
direction
Die lip
Velocity Magnitude (m/s)
X-Coordinate (m)
![Page 54: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/54.jpg)
Contours of Temperature distribution
Melt flow
direction
Die lip
![Page 55: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/55.jpg)
Contours of Shear rate and Viscosity
Melt flow
direction
Melt flow
direction
Die lipShear rate
Viscosity
![Page 56: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/56.jpg)
-3
0
3
0 10 20 30 40 50
-1
0
1
4 5 6 7
-1
0
1
24 25 26 27
-1
0
1
14 15 16 17
-1
0
1
44 45 46 47
-1
0
1
34 35 36 37
Simulated DieRequired Extrudate
Simulated die and required extrudate profiles
![Page 57: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/57.jpg)
0.00% 5.00% 10.00%
Out1Out2Out3Out4Out5Out6Out7Out8Out9Out1
Out
let
% of Mass Flow Rate
Designed Die Balanced Die
Percentage of mass flow rate for designed and balanced die
0
![Page 58: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/58.jpg)
Exploded view of the extrusion dieMelt pump
adapterAdapter 1
Adapter 2
Preland
Melt flow
direction
Dieland
![Page 59: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/59.jpg)
Blue prints
Whole die Melt pump adapter
Adapter 1
![Page 60: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/60.jpg)
Adapter 2 Spider
Die land
![Page 61: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/61.jpg)
ConclusionsThe optimum dimensions of the die to attain more balanced flow at the exit were obtained.The effect of inertia terms is found to be negligible for polymer flows at low Reynolds number.The exponent of the Carreau-Yasuda model, or the slope of the viscosity vs shear rate curve, has a significant effect on the die swell.The flow in the die appeared to be smooth with no re-circulation regions.
![Page 62: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/62.jpg)
Recommendations for future improvements
•Polymer viscoelastic properties•Include flow, cooling, solidification and vacuuming in and after the calibrator•Radiation effects for free surface flow •Pulling force at the end of the free surface•Pressure of the compressed air •Non-uniform mesh
![Page 63: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/63.jpg)
ACKNOWLEDGEMENTS
Prof. Milivoje KosticProf. Pradip Majumdar Prof. M.J. Kim Prof. Lou Reifschneider NICADD (Northern Illinois Centre for Accelerator and Detector Development), NIU Fermi National Accelerator Laboratory, Batavia, IL
![Page 64: Extrusion Simulation and Optimization of Profile Die Design 03-25-2003 Advisor Prof. Milivoje Kostic By Srinivasa Rao Vaddiraju.](https://reader035.fdocuments.in/reader035/viewer/2022062318/551a8ea1550346b52d8b5cd0/html5/thumbnails/64.jpg)
QUESTIONS ?