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The
Annual Technical
Conference, ANTEC 2004 Chicago, May 16-20,
organized by Society of Plastics
Engineers is the largest international gathering of individuals who
represent industry, government and academia in the field of plastics and
synthetic polymers.
* 1st
ANTEC 2004 Paper Title and
Abstract
Extrusion Simulation and
Experimental Validation to Optimize Precision Die Design
Srinivasa R. Vaddiraju*), M.
Kostic*), L. Reifschneider&), A.
Pla-Dalmau$), V. Rykalin%), and A.
Bross$)
*) Northern Illinois University (NIU); &)
Illinois State University, $) Fermi National Accelerator
Laboratory, %) NICADD-Northern Illinois Center for Accelerator and
Detector Development, NIU.
A CFD-simulation is
performed for an existing die and compared with the actual polymer flow and
dimensions of the extrudate. Experimental validation of the simulation is used
to improve new die design by integrating flow simulation through the 3-D die
geometry and the free-surface flow with swelling after the die. Modified
die-land-and-lip profile is optimized using the so-called “inverse extrusion”
simulation with an objective to improve accuracy of extrudate dimensions.
Full Paper (pdf)
Power Point Presentaiton [PPT]
* 2nd
ANTEC 2004 Paper Title and
Abstract
Computational Design of a U-Profile Die and Calibrator
Louis G. Reifschneider,
Illinois State University
Milivoje M. Kostic, Northern Illinois
University
Srinivasa Rao Vaddiraju, Northern Illinois University
The objectives of this work are three-fold: 1) to validate that an
open profile product can be made using simulation alone to design a die (design
rules of thumb are not applied), 2) assess the role of the calibrator in shaping
the free surface of the extrudate, and 3) quantify the heat transfer in a vacuum
calibrator and assess how such data can be used to design calibrators for other
products. The scope of this paper includes: 1) three-dimensional flow simulation
to design a die to make a U-shaped extrusion, 2) experimental trials to validate
the mass flow balance through the die and the cooling performance of the
calibrator, and 3) comparison of the heat transfer data obtained during
calibration trials to published data for profile
calibrators.
Full Paper (pdf)
Power Point Presentaiton [PPT]
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Fluent/ Polyflow UGM 2004 Paper Title and
Abstract
Optimization of a
Profile-Extrusion Die Design Using Inverse CFD Simulation
M. Kostic
and Srinivasa Rao Vaddiraju
Department of
Mechanical Engineering
NORTHERN ILLINOIS
UNIVERSITY
The challenges in modeling
polymer extrusion using CFD simulation lie in the areas of generating a
functional 3-D mesh-geometry, convergence problems due to high non-linearity of
material properties, and large computing time for the inverse simulation to
generate required die-land profile. The Polyflow® inverse extrusion
simulation is used for effective die design, by considering die-swell of a
polymer-melt within the free-surface flow. Numerical simulations are performed
to compute different results required for an optimal die design for a
rectangular extrudate profile with ten centerline holes, and to investigate
effects of different sections on mass-flow balance at the die exit.
Power Point Presentaiton [PPT]
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