Extrusion Simulation and Optimization of Profile Die Design03-25-2003AdvisorProf. Milivoje KosticBy Srinivasa Rao Vaddiraju

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 pumpA Schematic of Profile Extrusion Line at FNAL Introduction

Quality factorsExtrudate swell Draw down CoolingInsufficient mixing in the extruder Uneven die body temperatures and raw material variations Non-uniform viscosity in the dieNon-uniform swellingNon-uniform draw downrearrangement of the velocity profile as the polymer leaves the die

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

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

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

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

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

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

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

Design MethodologyUsing Finite Element based CFD code Polyflow Using the method of Inverse ExtrusionTo 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.

Literature ReviewThe 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 profileLouis 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.

Governing EquationsWhere, P is the pressure, is the extra stress tensor, v is the velocity.Continuity EquationMomentum Equation

Energy EquationWhere, Cv is the specific heat capacity of the material,T is the temperature, is the density,k is the thermal conductivity.the accumulation term, the convection term, the conduction term, the dissipation term,

Die DesignThe 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

POLYFLOW Finite-element CFD codePredict three-dimensional free surfaces Inverse extrusion capability Strong non-linearities Evolution procedure

Flowchart for numerical simulation using Polyflow1. Draw the geometry in Pro-E (or) other CAD software and export to GAMBIT2. Draw the geometry in GAMBIT (or) import from other CAD software and mesh it.3. Specify Polymer properties in Polydata4. Specify boundary conditions in Polydata8.Is the solution converged?Stop5. Specify remeshing technique and solver method in PolydataYesNo6. Specify the evolution parameters in Polydata7. Polyflow solves the conservation equations using the specified data and boundary conditionsModify the evolution parametersChange the remeshing techniques and/or solver methodsModify the mesh

General Assumptions and incompressible 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

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary ConditionsDie, 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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/hr and uniform inlet temperature (473 K or 200 C).

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary ConditionsInlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50kg/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 equationon freeOutlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.Alldomains: Viscous dissipation was neglected for all flow conditions (after verification).

Material DataZero shear rate viscosity, 0 = 36,580 Pa-sInfinite shear rate viscosity, = 0 Pa-sNatural time, = 0.902Transition Parameter, a = 0.585Exponent, n = 0.267Density, = 1040 Kg/m3Specific Heat, cp = 1200 J/Kg-KThermal Conductivity, k = 0.12307 W/m-KCoefficient of thermal expansion, = 0.5e-5 m/m-KStyron 663, mixed with Scintillator dopantsCarreau-Yasuda Law for viscosity data:Measured by, Datapoint Labs

Styron viscosity data, with and without Scintillator dopants

ProfilesRectangular profile die with one holeRectangular profile die with ten holes

Rectangular profile die with one holeALL DIMENSIONS ARE IN CMRequired extrudate is a rectangular cross section of 1cm2cm with a circular hole of 1.1 mm diameter at its center

Sensitivity analysis of die swell and inverse extrusion capabilities of Polyflow

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,

(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%

_1131881179.unknown

Full domain of the extrusion dieMelt flowdirection

Half domain of the extrusion die

Simulation domain with boundary conditions. Inlet (Fully Developed Flow)2. Wall (Vn = 0, Vs = 0)3. Symmetry (Vn = 0, Fs = 0). Free Surface (Fs = 0, Fn = 0, V.n = 0). Outlet (Fn = 0, Vs = 0)

Finite element 3-D domain and die-lip mesh30,872 elementsSkewness < 0.33

19 hours and 36 minutes of CPU timeWindows XP2.52 GHz Processor1 GB RAM

Contours of static pressure

Contours of velocity magnitude at different iso-surfaces

Contours of temperature distribution

Contours of shear rate

Existing die, corresponding simulation and new improved-die profiles

Exploded view of the extrusion die

2 D-View of the extrusion dieMelt flow direction

Blue printsPreland Dieland Pin

Rectangular profile die with ten holesALL DIMENSIONS ARE IN CMRequired extrudate is a rectangular cross section of 0.5cm10cm with ten equally spaced centerline circular holes of 1.1mm diameter.

Full domain of the extrusion dieMelt flowdirection

Half domain of the extrusion die

Simulation domain with boundary conditions

Finite element 3-D domain and half of extrudate profile mesh19,479 elementsSkewness < 0.5

Half domain of the extrusion die (without free surface) and division of outlet into 10 areas

Percentage of Mass flow rate in different exit segments

Chart1

0.04302964770.05086420870.03842304610.03385793830.03761987510.0366984290.03762471840.0373338483

0.11232121940.12374811270.10661268990.10173473660.10532921410.10494463040.10556807210.1050819092

0.11470281540.12506800670.10936730690.10514627790.10825770740.10800283290.1084647570.1080428696

0.10488677760.10365996950.10233273590.10392327250.10359142690.10333505020.10360476340.1037301664

0.1059166570.10365996950.10381302070.10578996490.10516830790.10494463040.10518184740.1053715683

0.10343850980.09834820090.10564728670.10685204850.10581193280.1058781870.10643707760.1062083615

0.10195805820.09672247780.10453707310.10575778060.1046534080.10462271440.10524621820.1050497248

0.10506700650.09960370990.11002378110.1122912040.10999549460.11041720320.10984872870.1098773776

0.10392126570.09854135610.10899401770.11135785780.10896569480.10945145510.10872224010.1088474784

0.10475804270.09978398810.11024904180.11328891890.11060693830.11170486740.10930157710.110456696

Case 1

Case 2

Case 3

Case 4

Case 5

Case 6

Case 7

Case 8

Outlet

% of mass flow rate

Sheet1

pro-ewholedie3wholedie4wholedie5wholedie6wholedie7wholedie8wholedie9wholedie10

stpwholedie6.stpwholedie41wholedie51wholedie61wholedie71wholedie81wholedie91wholedie101

GambitPreland1g2Preland1g3Preland1g4Preland1g5Preland1g6Preland1g7Preland1g8Preland1g9onlydie1s1onlydie1s1onlydie5

Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Mass flow rate(kg/s)

Case No.Case 1Case 2Case 3Case 4Case 5Case 6Case 7Case 8e-7

d05558535153535353

d11010101012141212

d29595959595959085

Out15.0385.954.53.97264.414.314.414.382.1466.6947.8747.3176

Out213.18414.5212.511.9412.3612.3112.3912.333.1887.5867.8748.22

Out313.4614.6712.8412.3412.712.6712.7412.683.1537.4677.8747.965

Out412.3112.1712.0112.212.1612.1312.1612.173.2057.4887.8747.703

Out512.4312.1812.1912.4112.3412.3112.3512.373.217.6557.8747.816

Out612.1411.5412.412.5412.4212.4212.4912.473.3487.877.8747.689

Out711.9611.3512.2712.4112.2812.2912.3512.333.3888.0437.8747.768

Out812.3311.68712.9113.1812.912.9612.8912.893.4998.2287.8747.71

Out912.19611.712.7913.0712.812.8412.75612.773.5228.327.8747.54

Out1012.2911.712.9413.312.9813.112.8312.963.5548.3577.8747.715

Total Average11.7311.7311.7311.7311.7311.7311.7311.737.771

Velocity at Outlet

0.32547365450.24280613320.37990986450.43735726740.38942707070.40013983280.38942707070.3926256369

0.01536500790.05657341330.00430908860.00032051070.00288459650.00244489360.0031658610.0026164141

0.02175184910.06282010190.00895467720.00270435470.00683828890.0064218430.00741390.0065592047

0.00244489360.00140704930.00056979680.00160546070.00134381930.00116285070.00134381930.0014070493

0.00356123030.00147173290.001537870.00336063850.00270435470.00244489360.00279374880.0029768978

0.001221720.00026236820.0032625230.00476841460.00346020760.00346020760.0041978910.0039798565

0.00038446750.00104947280.00211929540.00336063850.00219851460.00227918740.00279374880.0026164141

0.00261641410.00001343820.01011970820.0152805850.00994891450.01099548010.00977957440.0097795744

0.001578250.0000065410.0081661190.0130500920.00832092350.00895467720.00765065640.0078608707

0.00227918740.0000065410.01064081070.01791444180.01135596390.01364096550.00879405840.0109954801

0.37667667450.36641679190.42958975350.4997224040.43848265430.45194483150.43736032890.4414173987

0.05120301990.12361065870.0496798890.06236513660.04905558350.05180499870.04793325820.0487917618

Sheet1

0000

0000

0000

0000

0000

0000

0000

0000

0000

0000

case 1

case 2

case 3

case 4

Outlet

Avg vel(cm/s)

Flow Rates

0000

0000

0000

0000

0000

0000

0000

0000

0000

000

case 1

case 2

case 3

case 4

Outlet

Avg vel(cm/s)

Sheet3

000

000

000

000

000

000

000

000

000

000

case 3

case 5

case 6

Outlet

Avg vel(cm/s)

000

000

000

000

000

000

000

000

000

000

case 3

case 5

case 6

Outlet

Avg vel(cm/s)

0

0

0

0

0

0

0

0

0

0

onlydie1s1

Outlet

Avg vel(cm/s)

000

000

000

000

000

000

000

000

000

000

case 5

case 7

case 8

Outlet

Avg vel(cm/s)

00

00

00

00

00

00

00

00

00

00

onlydie5

avg

Outlet

Avg vel(cm/s)

pro-ewholedie3wholedie4wholedie5wholedie6wholedie7wholedie8wholedie9wholedie10

stpwholedie6.stpwholedie41wholedie51wholedie61wholedie71wholedie81wholedie91wholedie101

GambitPreland1g2Preland1g3Preland1g4Preland1g5Preland1g6Preland1g7Preland1g8Preland1g9onlydie5

Mass Flow rate in Kg/s (*e-6)e-7

Case No.Case 1Case 2Case 3Case 4Case 5Case 6Case 7Case 8

d05558535153535353

d11010101012141212

d29595959595959085

Out11.3371.581.1941.0521.1691.141.1691.167.3176

Out23.493.8443.3133.1613.2733.263.283.2658.22

Out33.5643.8853.39863.2673.3643.3553.373.3577.965

Out43.2593.223.183.2293.2193.213.2193.2237.703

Out53.2913.223.2263.2873.2683.263.2683.2747.816

Out63.2143.0553.2833.323.2883.2893.3073.37.689

Out73.1683.00453.24853.2863.2523.253.273.2647.768

Out83.26463.0943.4193.4893.4183.433.4133.4147.71

Out93.2293.0613.3873.463.3863.43.3783.3827.54

Out103.2553.09963.4263.523.4373.473.3963.4327.715

31.071631.063131.075131.07131.07431.06431.0731.07177.4436

Out14.30%5.09%3.84%3.39%3.76%3.67%3.76%3.73%9.45%10%

Out211.23%12.37%10.66%10.17%10.53%10.49%10.56%10.51%10.61%10%

Out311.47%12.51%10.94%10.51%10.83%10.80%10.85%10.80%10.28%10%

Out410.49%10.37%10.23%10.39%10.36%10.33%10.36%10.37%9.95%10%

Out510.59%10.37%10.38%10.58%10.52%10.49%10.52%10.54%10.09%10%

Out610.34%9.83%10.56%10.69%10.58%10.59%10.64%10.62%9.93%10%

Out710.20%9.67%10.45%10.58%10.47%10.46%10.52%10.50%10.03%10%

Out810.51%9.96%11.00%11.23%11.00%11.04%10.98%10.99%9.96%10%

Out910.39%9.85%10.90%11.14%10.90%10.95%10.87%10.88%9.74%10%

Out1010.48%9.98%11.02%11.33%11.06%11.17%10.93%11.05%9.96%10%

00000000

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Case 1

Case 2

Case 3

Case 4

Case 5

Case 6

Case 7

Case 8

Outlet

% of mass flow rate

Percentage of Mass Flow Rate in different exit segments

00

00

00

00

00

00

00

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Designed Die

Balanced Die

Outlet

% of Mass Flow Rate

Designed and Balanced Die

One hour of CPU timeWindows XP2.52 GHz Processor1 GB RAM

Contours of Static pressure

Contours of Velocity magnitude at different iso-surfaces and at centerline of exit

Contours of Temperature distribution

Contours of Shear rate and ViscosityShear rateViscosity

Simulated die and required extrudate profiles

Percentage of mass flow rate for designed and balanced die 0

Chart2

0.09448940910.1

0.10614175990.1

0.10284904110.1

0.09946593390.1

0.10092506030.1

0.09928515720.1

0.10030525440.1

0.09955632230.1

0.09736117640.1

0.09962088540.1

Designed Die

Balanced Die

Outlet

% of Mass Flow Rate

Sheet1

pro-ewholedie3wholedie4wholedie5wholedie6wholedie7wholedie8wholedie9wholedie10

stpwholedie6.stpwholedie41wholedie51wholedie61wholedie71wholedie81wholedie91wholedie101

GambitPreland1g2Preland1g3Preland1g4Preland1g5Preland1g6Preland1g7Preland1g8Preland1g9onlydie1s1onlydie1s1onlydie5

Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Avg Vel (cm/s)Mass flow rate(kg/s)

Case No.Case 1Case 2Case 3Case 4Case 5Case 6Case 7Case 8e-7

d05558535153535353

d11010101012141212

d29595959595959085

Out15.0385.954.53.97264.414.314.414.382.1466.6947.8747.3176

Out213.18414.5212.511.9412.3612.3112.3912.333.1887.5867.8748.22

Out313.4614.6712.8412.3412.712.6712.7412.683.1537.4677.8747.965

Out412.3112.1712.0112.212.1612.1312.1612.173.2057.4887.8747.703

Out512.4312.1812.1912.4112.3412.3112.3512.373.217.6557.8747.816

Out612.1411.5412.412.5412.4212.4212.4912.473.3487.877.8747.689

Out711.9611.3512.2712.4112.2812.2912.3512.333.3888.0437.8747.768

Out812.3311.68712.9113.1812.912.9612.8912.893.4998.2287.8747.71

Out912.19611.712.7913.0712.812.8412.75612.773.5228.327.8747.54

Out1012.2911.712.9413.312.9813.112.8312.963.5548.3577.8747.715

Total Average11.7311.7311.7311.7311.7311.7311.7311.737.771

Velocity at Outlet

0.32547365450.24280613320.37990986450.43735726740.38942707070.40013983280.38942707070.3926256369

0.01536500790.05657341330.00430908860.00032051070.00288459650.00244489360.0031658610.0026164141

0.02175184910.06282010190.00895467720.00270435470.00683828890.0064218430.00741390.0065592047

0.00244489360.00140704930.00056979680.00160546070.00134381930.00116285070.00134381930.0014070493

0.00356123030.00147173290.001537870.00336063850.00270435470.00244489360.00279374880.0029768978

0.001221720.00026236820.0032625230.00476841460.00346020760.00346020760.0041978910.0039798565

0.00038446750.00104947280.00211929540.00336063850.00219851460.00227918740.00279374880.0026164141

0.00261641410.00001343820.01011970820.0152805850.00994891450.01099548010.00977957440.0097795744

0.001578250.0000065410.0081661190.0130500920.00832092350.00895467720.00765065640.0078608707

0.00227918740.0000065410.01064081070.01791444180.01135596390.01364096550.00879405840.0109954801

0.37667667450.36641679190.42958975350.4997224040.43848265430.45194483150.43736032890.4414173987

0.05120301990.12361065870.0496798890.06236513660.04905558350.05180499870.04793325820.0487917618

Sheet1

0000

0000

0000

0000

0000

0000

0000

0000

0000

0000

case 1

case 2

case 3

case 4

Outlet

Avg vel(cm/s)

Flow Rates

0000

0000

0000

0000

0000

0000

0000

0000

0000

000

case 1

case 2

case 3

case 4

Outlet

Avg vel(cm/s)

Sheet3

000

000

000

000

000

000

000

000

000

000

case 3

case 5

case 6

Outlet

Avg vel(cm/s)

000

000

000

000

000

000

000

000

000

000

case 3

case 5

case 6

Outlet

Avg vel(cm/s)

0

0

0

0

0

0

0

0

0

0

onlydie1s1

Outlet

Avg vel(cm/s)

000

000

000

000

000

000

000

000

000

000

case 5

case 7

case 8

Outlet

Avg vel(cm/s)

00

00

00

00

00

00

00

00

00

00

onlydie5

avg

Outlet

Avg vel(cm/s)

pro-ewholedie3wholedie4wholedie5wholedie6wholedie7wholedie8wholedie9wholedie10

stpwholedie6.stpwholedie41wholedie51wholedie61wholedie71wholedie81wholedie91wholedie101

GambitPreland1g2Preland1g3Preland1g4Preland1g5Preland1g6Preland1g7Preland1g8Preland1g9onlydie5

Mass Flow rate in Kg/s (*e-6)e-7

Case No.Case 1Case 2Case 3Case 4Case 5Case 6Case 7Case 8

d05558535153535353

d11010101012141212

d29595959595959085

Out11.3371.581.1941.0521.1691.141.1691.167.3176

Out23.493.8443.3133.1613.2733.263.283.2658.22

Out33.5643.8853.39863.2673.3643.3553.373.3577.965

Out43.2593.223.183.2293.2193.213.2193.2237.703

Out53.2913.223.2263.2873.2683.263.2683.2747.816

Out63.2143.0553.2833.323.2883.2893.3073.37.689

Out73.1683.00453.24853.2863.2523.253.273.2647.768

Out83.26463.0943.4193.4893.4183.433.4133.4147.71

Out93.2293.0613.3873.463.3863.43.3783.3827.54

Out103.2553.09963.4263.523.4373.473.3963.4327.715

31.071631.063131.075131.07131.07431.06431.0731.07177.4436

Out14.30%5.09%3.84%3.39%3.76%3.67%3.76%3.73%9.45%10%

Out211.23%12.37%10.66%10.17%10.53%10.49%10.56%10.51%10.61%10%

Out311.47%12.51%10.94%10.51%10.83%10.80%10.85%10.80%10.28%10%

Out410.49%10.37%10.23%10.39%10.36%10.33%10.36%10.37%9.95%10%

Out510.59%10.37%10.38%10.58%10.52%10.49%10.52%10.54%10.09%10%

Out610.34%9.83%10.56%10.69%10.58%10.59%10.64%10.62%9.93%10%

Out710.20%9.67%10.45%10.58%10.47%10.46%10.52%10.50%10.03%10%

Out810.51%9.96%11.00%11.23%11.00%11.04%10.98%10.99%9.96%10%

Out910.39%9.85%10.90%11.14%10.90%10.95%10.87%10.88%9.74%10%

Out1010.48%9.98%11.02%11.33%11.06%11.17%10.93%11.05%9.96%10%

00000000

00000000

00000000

00000000

00000000

00000000

00000000

00000000

00000000

00000000

Case 1

Case 2

Case 3

Case 4

Case 5

Case 6

Case 7

Case 8

Outlet

% of mass flow rate

Percentage of Mass Flow Rate in different exit segments

00

00

00

00

00

00

00

00

00

00

Designed Die

Balanced Die

Outlet

% of Mass Flow Rate

Designed and Balanced Die

Exploded view of the extrusion die

Blue printsWhole die Melt pump adapter Adapter 1

Adapter 2 Spider Die land

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.

Recommendations for future improvements Polymer viscoelastic propertiesInclude flow, cooling, solidification and vacuuming in and after the calibratorRadiation effects for free surface flow Pulling force at the end of the free surfacePressure of the compressed air Non-uniform mesh

ACKNOWLEDGEMENTSProf. 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

QUESTIONS ?