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Automatic Design of Extrusion Dies

The design of extrusion dies is a time consuming process with a huge necessity for practical knowledge. The use of CFD-Systems to simulate the flow behavior of polymer melts within an extrusion die is more and more introduced in research and industrial applications and has developed to an important area of application in the design of such systems. The goal of this research work is the integrative coupling of different software systems for fully automized design of a spiral mandrel die on the basis of a parameterized, associative 3D-CAD-model. To interpret the quality of the different design proposals the objective is formulated, to introduce an automatically calculable, scalar target criterion for the die quality (Die Quality Criterion - DQC). In a manual computer aided optimization of a prototype flat spiral die for the blown film extrusion, different scalar quality criteria are analyzed to prepare the automization.

The projection exactness of the different quality-criteria is verified in several practical tests by using a manual optimized prototype flat spiral die in a blown film extrusion line. The conformity of theoretically calculated values with real measurements is very high.

In a second focus of this research work a process is implemented to perform the design of an extrusion die completely automized. Therefore different software-systems are coupled integratively. A superior master system steers different partial functions (geometry-variation, flow-simulation and interpretation) on the basis of implemented program routines and calculates a die quality criterion. New design proposals are suggested by a heuristic optimization algorithm, so that this process is running in an iteration loop until the optimum is found or termination criteria are reached. For the validation of the optimization-procedure, existing spiral mandrel die geometry is used. The automized procedure calculates an optimal design proposal independent on user interactions.This optimization task is solved robustly and without interruptions. The design proposal corresponds very well with manual design studies of such distributor systems so that the correctness of the solution can be verified.

Lesen Sie die deutsche Zusammenfassung auf
 Kenny Saul

Kenny Saul
Lehrstuhl für Konstruktion und Kunststoffmaschinen
Universität Duisburg-Essen


Free keywords: Extrusion, Spiral-Mandrel-Dies, Single-Screw Extrusion, Pipe Extrusion, Film Extrusion, Blown Film Extrusion, Design of Extrusion Dies, Computational Fluid Dynamics, CFD, Computer Aided Optimization, Extrusion Die Optimiziation, Flat-Distributor, Design of Spiral-Mandrel-Dies, Extrusion-Dies, Automization, CFD, Integrative Interconnection
Institute / chair: Fakultät für Ingenieurwissenschaften, Abteilung Maschinenbau und Verfahrenstechnik der Universität Duisburg-Essen
Language: German
Technical consultant for expert services: Prof. Dr.-Ing. Johannes Wortberg (Betreuer), Prof. Dr.-Ing. Dr.-Ing. E.h. Walter Michaeli
Publication year: 2011
Provider: Wissenschaftlicher Arbeitskreis Kunststofftechnik (WAK) /

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