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Extrusion Die Design Optimization Including Viscoelastic Polymer Simulation

Parametric Study of Die Lip Profile. The effect of non-zero nitrogen pressure in inside-surface holeThe effect of non-zero normal force in the outlet of the free surface flow domainThe effect of the length of the free surface flow domain. Improvement of Extrusion Simulation. Apply fine enough non-

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Extrusion Die Design Optimization Including Viscoelastic Polymer Simulation

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    1. Extrusion Die Design Optimization Including Viscoelastic Polymer Simulation Prepared by Dan Wu with the supervision under Prof. M. Kostic

    2. Parametric Study of Die Lip Profile The effect of non-zero nitrogen pressure in inside-surface hole The effect of non-zero normal force in the outlet of the free surface flow domain The effect of the length of the free surface flow domain

    3. Geometry of the quarter computational domain

    5. Flow Boundary Conditions The flow inlet is given by fully developed volumetric flow rate At the walls the flow is given as zero velocity, i.e. vn = vs = 0 A symmetry plane with zero tangential forces and zero normal velocity, fs = vn =0 are applied at half plane of the geometry. Free surface is specified for the moving boundary conditions of the die with atmospheric pressure, p = p?.The different pressure (N2 gage pressure) in inside-surface of the hole will be applied in our new simulation Exit for the flow is specified as, fs = fn = 0. The different normal force (pulling force) will be applied in our new simulation.

    6. Mesh Refinement in the computational domain

    7. Curve-fitting viscosity function

    9. Non-isothermal generalized Newtonian flow setting up In PolyFLOW inverse simulation MATERIAL DATA   Density (?) 1040 kg/m3 Specific Heat (H) 1200 J/Kg-oK Thermal Conductivity (k) 0.1231 W/m-oK Coefficient of Thermal Expansion (?) 6.6 x 10-5 m/m-oK Reference Temperature (theta or T?) 300K

    10. Parameters in the new general form

    11. Current simulation results analysis (Carreau-Yasuda model)

    12. Die lip profile comparison by using our current and previous mesh

    13. Parametric Study of Die Lip Profile (1) free surface length The free surface length range: 0.5-2 inches Influence of the free surface length is minimal in the simulation results The free surface length 1 inches is selected to pursue the following parametric study

    14. Parametric Study of Die Lip Profile (2) nitrogen pressure in inside-surface hole

    15. Parametric Study of Die Lip Profile (3) normal force at the outlet of the free surface flow domain

    16. Parametric Study of Die Lip Profile (3) pressure in the outlet of the free surface flow domain (Cont’d)

    17. Extrusion simulation including viscoelastic properties

    18. Curve fitting to the parameters with Giesekus model

    19. Curve fitted parameters with Giesekus model

    20. Geometry, mesh and Boundary Conditions of the computational flow domain

    21. Comparison of the 2-D inverse extrusion results

    22. First try for 3-D inverse extrusion applying Giesekus model

    23. The comparison of the simulation results

    24. Improve the curve fitted parameters with 1-mode Giesekus model

    25. The simulation of the die land and free surface flow domain without the central hole

    26. The extrudate swelling in the real extrusion experiment

    27. Comparison of the bottom views of the extrudate swelling

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