Towards shape optimization of profile extrusion dies with respect to homogeneous die swell

2013 ◽  
Vol 200 ◽  
pp. 79-87 ◽  
Author(s):  
L. Pauli ◽  
M. Behr ◽  
S. Elgeti
2013 ◽  
Vol 554-557 ◽  
pp. 794-800 ◽  
Author(s):  
Roland Siegbert ◽  
Stefanie Elgeti ◽  
M. Behr ◽  
K. Kurth ◽  
C. Windeck ◽  
...  

Abstract. The rather unintuitive and non-linear behavior of plastics melts is a well-known obstacle in the design and manufacturing cycle of profile extrusion dies. This is reflected, for example, in the so-called running-in experiments, in which the already manufactured die is modified up to 15 times until the final product, shaped by the die, matches the quality requirements. Besides a homogeneous outflow velocity and thus homogeneous material distribution, an appropriate die swell is a second design objective which complicates the reworking of the manufactured die. We are conducting work to shorten the manual running-in process by the means of numerical shape optimization, making this process significantly less costly and more automatic. From a numerical point of view, the extrusion process is not as challenging as high-speed flows, since it can be described by steady Stokes equations without major loss of accuracy. The drawback, however, is the need for ac- curate modeling of the plastics behavior, which generally calls for shear-thinning or even viscoelastic models, as well as for 3D computations, leading to large computational grids. The intention of this paper is to investigate the application of specific geometry features in extrusion dies and their influence on objective functions in an optimization framework. However, representative objective functions concerning die swell and the incorporation of known geometry features, as used by experienced die designers, into the optimization framework still remain a challenge. Hence, the topics discussed are the influence of the mentioned geometry features on existing objective functions as well as an outlook on an algorithmic implementation into the optimization process with regard to representative objective functions.


2016 ◽  
Author(s):  
Roland Siegbert ◽  
Marek Behr ◽  
Stefanie Elgeti

2015 ◽  
Vol 799-800 ◽  
pp. 261-265
Author(s):  
Tao Huang ◽  
Yan He ◽  
Yi Nie ◽  
Yan Wang ◽  
Yueh Jaw Lin ◽  
...  

Polymer extrusion is one of the most widely utilized manufacturing processes across many industries including automotive, architecture, aerospace etc. However, in order to maintain normal operations, polymer extrusion dies are conventionally designed with large dimensions and thick walls which results in the overweight of them. In this paper, a shape optimization method is proposed to reduce the weight of polymer extrusion dies without sacrificing the required performances of extrudate. Firstly, Finite element simulation of the extrusion process is conducted using the commercial software HyperXtrude to study both the essential flow characteristics of polymer melts and the deformation and stress distribution of extrusion die. Secondly, shape optimization is conducted to find the minimum weight of extrusion die while satisfying the required properties and productivity of polymer product. The extrusion die is then redesigned according to the result of shape optimization and compared with the original one. A Medium-sized polymer profile extrusion die is selected as case study, the result of which shows that the weight of the extrusion die is reduced by 31.6%,though the maximal deformation and stress of the die are increased by 1.7% and 16.1% respectively. The proposed approach is demonstrated to be effective for the lightweight design of polymer extrusion die.


PAMM ◽  
2014 ◽  
Vol 14 (1) ◽  
pp. 789-794 ◽  
Author(s):  
Roland Siegbert ◽  
Johannes Kitschke ◽  
Hatim Djelassi ◽  
Marek Behr ◽  
Stefanie Elgeti

2017 ◽  
Vol 23 (10) ◽  
pp. 5093-5104 ◽  
Author(s):  
Guobao Jin ◽  
Yifei Jin ◽  
Danyang Zhao ◽  
Guanghui Dai ◽  
Qingqing Zhang

2016 ◽  
Vol 136 (8) ◽  
pp. 343-347 ◽  
Author(s):  
Ryo Sakai ◽  
Hiroaki Imai ◽  
Masayuki Sohgawa ◽  
Takashi Abe

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