scholarly journals Internal Flow Optimization in a Complex Profile Extrusion Die Using Flow Restrictors and Flow Separators

2021 ◽  
Author(s):  
Jingyang Xing ◽  
Majed Alsarheed ◽  
Animesh Kundu ◽  
John P. Coulter
Keyword(s):  
Velocity Distribution ◽  
Cross Flow ◽  
Internal Flow ◽  
Outer Wall ◽  
Die Design ◽  
Cross Sectional ◽  
Polymer Flow ◽  
Extrusion Dies ◽  
Flow Imbalance ◽  
Distinct Features

Abstract The control of flow balance at the die exit is the key for successful extrusion of polymers. The complex cross-sectional variation in real-world hollow extrusion profiles intrinsically promotes flow imbalance in the die cavity. Special considerations are required for designing extrusion dies for such profiles. The die design for a complex door frame profile was computationally optimized in this study with the aid of a commercially available software package. The velocity distribution at the die exit, post-die extrudate deformation, temperature distribution, and pressure distribution of a traditional die was investigated in detail and found to be inadequate. A modified die incorporated three distinct features, flow restrictors, flow separators and approach angle of the torpedoes, to achieve a balanced and uniform velocity at the die exit. The flow restrictors and flow separators were added in the pre-parallel zone. Flow restrictors were added on top and bottom of the torpedoes to increase the restriction on polymer flow. A unique inclined flow restrictor was introduced to achieve uniform internal melt flow. Flow separators were added at junctions of outer wall and inner vertical walls to separate the polymer flow into different sections and minimize cross flow between these sections. The addition of these features proved to be highly effective for balancing the velocity distribution at the die exit. The combination of 3-D modeling and simulation is an effective cost and time efficient approach for optimizing complex die designs before manufacturing.

Computer-aided design and optimization of profile extrusion dies for thermoplastics and rubber: a review

2011 ◽  
Vol 225 (4) ◽  
pp. 280-321 ◽  
Author(s):  
J F T Pittman
Keyword(s):  
Design Optimization ◽  
Computer Aided Design ◽  
Cross Flow ◽  
Wall Slip ◽  
Economic Benefits ◽  
Die Design ◽  
Computer Assisted ◽  
Extrudate Swell ◽  
Design And Optimization ◽  
Extrusion Dies

A review is provided of issues and techniques in design and optimization of profile extrusion dies for thermoplastics and rubber, with particular emphasis on unplasticized polyvinyl chloride and rubber compounds. Traditional profile die design methods are contrasted with computer-based ones, with respect to efficiency and economic benefits. The main types of die construction are outlined. Physical phenomena relevant to the design and performance of dies are summarized, including: rheology and kinematics of the flow, wall slip, extrusion instabilities, residence time and degradation, extrudate swell, draw-down, and thermal effects. Approaches and strategies for die design are explained, including: flow balancing – with guidance from analytic flow results, the Avoid-Cross-Flow strategy, use of flow separators, and designing for extrudate swell. Published computer simulations of die flow used to assist with design are reviewed. Introducing automatic die design, the structure and elements of a computerized design optimization environment are set out. Key components and options within this are described, including: objective functions, constraints, design variables, optimization algorithms, design parameterization and flow domain meshing, and optimization strategies. Published implementations of computerized profile die design optimization are described. Automatic design optimization is compared with the work of a designer assisted by flow simulations in the industrial environment, showing how substantial reductions in demands on the designer's time are possible. The nature and potential of robust design is outlined, with techniques for its implementation. Conclusions are drawn as to the present state of the art in computer-assisted profile die design and optimization, and potential advances.

scholarly journals Research of Flow Field of Alkaline/Surfactant/Polymer Solution in the Annular Depressurization Slot by PIV Experiment

2018 ◽  
Vol 2018 ◽  
pp. 1-7
Author(s):  
Cheng Fu ◽  
Tingting Zhu ◽  
Di Wu ◽  
Ying Wang ◽  
Bin Huang
Keyword(s):  
Flow Field ◽  
Velocity Distribution ◽  
Internal Flow ◽  
Outer Wall ◽  
Vortex Center ◽  
Experimental Conditions ◽  
Molecular Weights ◽  
New Research ◽  
Principle Of Similarity ◽  
Alkaline Surfactant Polymer

In order to study the flow field changes of ASP (alkaline/surfactant/polymer) solutions with different molecular weights and flow rates when flowing through the annular depressurization slot in the laboratory, the annulus pipeline model was designed based on the principle of similarity. The particle image velocimetry (PIV) system was used to continuously capture the transient images when the ASP solution flows in the model under different experimental conditions. Tecplot software was used to analyze and process the nephrograms of the velocity distribution of ASP solution when flowing through the partially pressured injection tool with different depressurization slots. The experimental results showed that the vortex occurred at the bottom of the depressurization slots; the greater the flow rate, the closer the vortex center to the outer wall; higher molecular weight of the polymer in the ASP solution caused larger velocity gradient towards the wall. The number of the slots has no significant effect on the position of the vortex. This experiment provides a new research method for the velocity distribution of the internal flow field in the partially pressured injection tool.

scholarly journals A Multi-Rheology Design Method of Sheeting Polymer Extrusion Dies Based on Flow Network and the Winter–Fritz Design Equation

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 1924
Author(s):  
Amin Razeghiyadaki ◽  
Dongming Wei ◽  
Asma Perveen ◽  
Dichuan Zhang
Keyword(s):  
Velocity Distribution ◽  
Power Law ◽  
Die Design ◽  
Rheological Parameters ◽  
Process Conditions ◽  
Geometrical Parameters ◽  
Polymer Extrusion ◽  
Flow Network ◽  
Extrusion Dies ◽  
Percent Improvement

In the polymer sheet processing industry, the primary objective when designing a coat-hanger die is to achieve a uniform velocity distribution at the exit of the extrusion die outlet. This velocity distribution depends on the internal flow channels of the die, rheological parameters and extrusion process conditions. As a result, coat-hanger dies are often designed for each polymer based on its individual rheological data and other conditions. A multi-rheology method based on a flow network model and the Winter–Fritz equation is proposed and implemented for the calculation, design and optimization of flat sheeting polymer extrusion dies. This method provides a fast and accurate algorithm to obtain die design geometries with constant wall-shear rates and optimal outlet velocity distributions. The geometric design when complemented and validated with fluid flow simulations could be applied for multi-rheological fluid models such as the power-law, Carreau–Yasuda and Cross. This method is applied to sheet dies with both circular- and rectangular-shaped manifolds for several rheological fluids. The designed geometrical parameters are obtained, and the associated fluid simulations are performed to demonstrate its favorable applicability without being limited to only the power-law rheology. The two such designed dies exhibit 32.9 and 21.5 percent improvement in flow uniformity compared to the previous methods for dies with circular and rectangular manifolds, respectively.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

scholarly journals Attenuation of Cross-Flow Fan Noise Using Porous Stabilizers

2011 ◽  
Vol 2011 ◽  
pp. 1-10 ◽  
Author(s):  
Huanxin Lai ◽  
Meng Wang ◽  
Chuye Yun ◽  
Jin Yao
Keyword(s):  
Cross Flow ◽  
Sound Radiation ◽  
Internal Flow ◽  
Considerable Effect ◽  
Front Wall ◽  
Performance Curve ◽  
Fan Noise ◽  
Aerodynamic Performances ◽  
The Cross ◽  
Cross Flow Fan

This paper presents a qualitative analysis of controlling the cross-flow fan noise by using porous stabilizers. The stabilizer was originally a folded plate. It is changed into a porous structure which has a plenum chamber and vent holes on the front wall. In order to investigate the influences of using the porous stabilizers, experiments are carried out to measure the cross-flow fan aerodynamic performances and sound radiation. Meanwhile, the internal flow field of the fan is numerically simulated. The results show that the porous stabilizers have not produced considerable effect on the cross-flow fan's performance curve, but the noise radiated from the fan is strongly affected. This indicates the feasibility of controlling the cross-flow fan noise by using the porous stabilizers with selected porosity.

scholarly journals Numerical Simulation and Experimental Study on Flow Field in a Swirl Nozzle

2021 ◽  
Vol 2021 ◽  
pp. 1-9
Author(s):  
Yicheng Sun ◽  
Yufan Fu ◽  
Baohui Chen ◽  
Jiaxing Lu ◽  
Wanquan Deng
Keyword(s):  
Flow Field ◽  
Velocity Distribution ◽  
Flow Characteristics ◽  
Internal Flow ◽  
Low Pressure ◽  
External Flow ◽  
Droplet Velocity ◽  
Inlet Pressure ◽  
Outlet Section ◽  
Local Pressure

In order to study the internal flow characteristics and external droplet velocity distribution characteristics of the swirl nozzle, the following methods were used: numerical simulations were used to study the internal flow characteristics of a swirl nozzle and phase Doppler particle velocimetry was used to determine the corresponding external droplet velocity distribution under medium and low pressure conditions. The distributions of pressure and water velocity inside the nozzle were obtained. Meanwhile, the velocities of droplets outside the nozzle in different sections were discussed. The results show that the flow rate in the swirl nozzle increases with the increase in inlet pressure, and the local pressure in the region decreases because of the excessive velocity at the internal outlet section of the swirl nozzle, resulting in cavitation. The experimental results show that under an external flow field, the minimum droplet velocity occurs in the axial direction; starting from the axis, the velocity first increases and then decreases along the radial direction. Swirling motion inside the nozzle and velocity variations in the external flow field occur under medium and low pressure conditions. The relationship between the inlet pressure and the distributions of water droplets’ velocities was established, which provides a reference for the research and development of the swirl nozzle.

Secondary Flow Loss Reduction Method by Use of Endwall Contouring in Gas Turbine Cascade Using Optimization Method

2021 ◽  
Author(s):  
Kazuki Yamamoto ◽  
Ryota Uehara ◽  
Shohei Mizuguchi ◽  
Masahiro Miyabe
Keyword(s):  
Boundary Layer ◽  
Secondary Flow ◽  
Gas Turbines ◽  
Cross Flow ◽  
Internal Flow ◽  
Optimization Method ◽  
Loss Reduction ◽  
Turbine Cascade ◽  
Flow Loss ◽  
Endwall Contouring

Abstract High efficiency is strongly demanded for gas turbines to reduce CO2 emissions. In order to improve the efficiency of gas turbines, the turbine inlet temperature is being raised higher. In that case, the turbine blade loading is higher and secondary flow loss becomes a major source of aerodynamic losses due to the interaction between the horseshoe vortex and the strong endwall cross flow. One of the authors have optimized a boundary layer fence which is a partial vane to prevent cross-flow from pressure-side to suction-side between blade to blade. However, it was also found that installing the fence leads to increase another loss due to tip vortex, wake and viscosity. Therefore, in this paper, we focused on the endwall contouring and the positive effect findings from the boundary layer fence were used to study its optimal shape. Firstly, the relationship between the location of the endwall contouring and the internal flow within the turbine cascade was investigated. Two patterns of contouring were made, one is only convex and another is just concave, and the secondary flow behavior of the turbine cascade was investigated respectively. Secondly, the shape was designed and the loss reduction effect was investigated by using optimization method. The optimized shape was manufactured by 3D-printer and experiment was conducted using cascade wind tunnel. The total pressure distributions were measured and compared with CFD results. Furthermore, flow near the endwall and the internal flow of the turbine cascade was experimentally visualized. The internal flow in the case of a flat wall (without contouring), with a fence, and with optimized endwall contouring were compared by experiment and CFD to extract the each feature.

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