Improved inverse design method for thin-wall hollow profiled polymer extrusion die based on FEM-CFD simulations

Zhang, Guangdong; Huang, Xiang; Li, Shuanggao; Xia, Chao; Deng, Tong

doi:10.1007/s00170-019-04785-w

Cited by 7 publications

(3 citation statements)

References 29 publications

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“…The interpolation scheme selects DEVSS SU [21] and mini-element to solve the stress, velocity and pressure field. In addition, the mesh deformation of each interface and free surface in the free extrusion area of the wall may cause the mesh to be too large, so the Optimesh-3D remeshing technology [22] is used to continuously reset and optimize the mesh.…”

Section: Calculation Strategymentioning

confidence: 99%

Viscoelastic Numerical Simulation Study on the Co-Extrusion Process of Tri-Composite Tire Tread

Wang

Zhou

et al. 2023

Materials

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The co-extrusion process is widely used to produce composite tire treads with better performance. This study investigated the rubber co-extrusion flow process and quality influencing factors of tri-composite tire tread through numerical simulation and experimental methods. Here, RPA 2000 rubber processing analyzer was used to carry out rheological tests on the three rubber materials, the PTT viscoelastic constitutive model was fitted, and the fitting curves were in good agreement with the test data. Then, a three-dimensional viscoelastic numerical simulation model of the tri-composite tread co-extrusion process was established using Ansys Polyflow software. The parameter evolution technique is adopted in the model establishment to improve the calculation convergence. In addition, a global remeshing function is used to avoid excessive mesh deformation. A co-extrusion experiment is conducted to verify the model’s accuracy using a tri-screw extruder. The extruded tread size error rate between the experiment and simulation is less than 6%. The variation of the velocity field, pressure field and shear rate field during extrusion is analyzed, and the formation mechanism of die swell is explained simultaneously. Finally, the influence of process parameters (inflow rate and traction speed) and die structure (convergence angle and thickness) on the extruded tire tread shape and quality was investigated, which can provide theoretical guidance for improving tread quality and production efficiency. Furthermore, the numerical simulation method can assist the design of the die plate in enhancing the efficiency of the die plate design.

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Section: Calculation Strategymentioning

confidence: 99%

Viscoelastic Numerical Simulation Study on the Co-Extrusion Process of Tri-Composite Tire Tread

Wang

Zhou

et al. 2023

Materials

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“…Due to the existence of a free surface and moving interfaces, the numerical solutions of the design point may be non-convergent, which leads to the non-convergence of the optimal design. Additionally, the existing commercial software, namely ANSYS Polyflow, does not support the inverse design method for more than two free surfaces [ 26 , 27 ], so the application of the inverse design with a free surface and moving interface for the coextrusion die can be implemented using any commercial software directly.…”

Section: Introductionmentioning

confidence: 99%

Improved Optimization of a Coextrusion Die with a Complex Geometry Using the Coupling Inverse Design Method

2023

Self Cite

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The main challenge in a polymer coextrusion process is to have a good die design prior to the process, which can minimize the geometric errors that are caused by extrusion swell and interface motion. For this purpose, a coupling method of optimization and inverse design for a coextrusion die was studied for a medical striped catheter. In the study, the main material was thermoplastic polyurethane (TPU), and the auxiliary material was TPU filled with 30 wt% barium sulfate. An overall optimization design method was used to optimize the geometry of the extrusion die channel for the striped catheter, which had a complex geometry. In the global optimization process, the local inverse design method was used to design the inlet of the auxiliary material. The non-linear programming by quadratic Lagrangian (NLPQL) algorithm was used to obtain the optimal geometric solution of the coextrusion die runner. The experimental verification results showed that the coupling method for coextrusion die design improved the design efficiency of the coextrusion die remarkably. The value of the objective function, which was used to measure the geometric error of the product, was reduced by 72.3% compared with the initial die design.

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“…The swell behavior and physical properties of polymer melts emerging from a 3D hollow extrusion die is numerically studied by Mu et al, [5][6][7][8] using a multi-mode differential Phan-Thien Tanner (PTT) model. Zhang et al [9] proposed an inverse design method for thin-walled hollow profile extrusion dies.…”

Section: Introductionmentioning

confidence: 99%

Numerical Study of Residual Stresses Due to External Cooling in Extruded Polymer Profiles

Spanjaards

Hulsen

Anderson

2022

Macro Theory & Simulations

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Profile extrusion is a production technique to make polymer profiles and hollow tubes. At a certain distance after the die exit the polymer extrudate is guided into a cooling chamber, where the polymer is cooled extensively to set the part dimensions. Uniform cooling in the cooling chamber is required to avoid warpage and twisting of the extrudate due to differential shrinkage. The effect of extrudate cooling on the shape of the extrudate and the residual stresses in the final extrudate product are numerically studied. Two different cases are studied: a 2D axisymmetric problem of a viscoelastic fluid exiting an annular die and a 3D problem of a hollow square shaped die. The extrudate is extensively cooled from a distance L c from the die exit. Extrudate cooling is modeled by subjecting the extrudate to heat loss via convection. For L die < z ≤ L c the Nusselt number Nu is fixed to 1 to represent the part of the extrudate in between the die exit and the entrance of the cooling chamber. For z > L c the Nusselt number is varied to mimic different cooling speeds. The Weissenberg number Wi, the Nusselt number and L c are varied in this work. Results show that for high values of Wi a significant skin-effect of high residual stresses appear near the extrudate edges for high Nusselt numbers and small values of L c . It is also shown that for high Weissenberg numbers the shape of the extrudate is significantly altered due to extrudate swell, when the extrudate is cooled slower. For fast cooling and small values of L c , the polymer does not have time to relax and the elastic stresses are "frozen in." This leads to less extrudate swell but large residual stresses near the extrudate edges.

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Improved inverse design method for thin-wall hollow profiled polymer extrusion die based on FEM-CFD simulations

Cited by 7 publications

References 29 publications

Viscoelastic Numerical Simulation Study on the Co-Extrusion Process of Tri-Composite Tire Tread

Viscoelastic Numerical Simulation Study on the Co-Extrusion Process of Tri-Composite Tire Tread

Improved Optimization of a Coextrusion Die with a Complex Geometry Using the Coupling Inverse Design Method

Numerical Study of Residual Stresses Due to External Cooling in Extruded Polymer Profiles

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