Extrusion Die Design Optimization Including Viscoelastic Polymer Simulation

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www.kostic.niu.edu/extrusion. Parametric Study. Effect of hole non-zero nitrogen pressureEffect of non-zero normal force in the outlet of the free surfaceEffect of the length of the free surface flow domain. Simulation Improvement-Refined non-uniform mesh. Fine non-uniform mesh in the corner area and in the axial flow-direction after the die exitConvective and Radiation heat transfer in the free surface.

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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 Fluent UGM 2004

2. www.kostic.niu.edu/extrusion Parametric Study Effect of hole non-zero nitrogen pressure Effect of non-zero normal force in the outlet of the free surface Effect of the length of the free surface flow domain

3. www.kostic.niu.edu/extrusion Geometry of the quarter computational domain

4. www.kostic.niu.edu/extrusion

5. www.kostic.niu.edu/extrusion 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. www.kostic.niu.edu/extrusion Mesh Refinement in the computational domain

7. www.kostic.niu.edu/extrusion 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

8. www.kostic.niu.edu/extrusion

9. www.kostic.niu.edu/extrusion Current simulation results analysis (Carreau-Yasuda model)

10. www.kostic.niu.edu/extrusion Die lip profile comparison by using our current and previous mesh

11. www.kostic.niu.edu/extrusion 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

12. www.kostic.niu.edu/extrusion Parametric Study of Die Lip Profile (2) nitrogen pressure in inside-surface hole

13. www.kostic.niu.edu/extrusion Parametric Study of Die Lip Profile (3) normal force at the outlet of the free surface flow domain

14. www.kostic.niu.edu/extrusion Parametric Study of Die Lip Profile (3) pressure in the outlet of the free surface flow domain (Cont’d)

15. www.kostic.niu.edu/extrusion Extrusion simulation including viscoelastic properties

16. www.kostic.niu.edu/extrusion Curve fitting to the parameters with Giesekus model

17. www.kostic.niu.edu/extrusion Curve fitted parameters with Giesekus model

18. www.kostic.niu.edu/extrusion Geometry, mesh and Boundary Conditions of the computational flow domain

19. www.kostic.niu.edu/extrusion Comparison of the 2-D inverse extrusion results

20. www.kostic.niu.edu/extrusion First try for 3-D inverse extrusion applying Giesekus model

21. www.kostic.niu.edu/extrusion The comparison of the simulation results

22. www.kostic.niu.edu/extrusion Improve the curve fitted parameters with 1-mode Giesekus model

23. www.kostic.niu.edu/extrusion The simulation of the die land and free surface flow domain without the central hole

24. www.kostic.niu.edu/extrusion Comparison of the bottom views of the extrudate swelling

25. www.kostic.niu.edu/extrusion Conclusions Optimum profile of the Die lip Influence of different parameters on the die-lip profile (parametric study) Final simulation including viscoelastic properties of Styron663 with Sintillator popants

26. www.kostic.niu.edu/extrusion Recommendation for future research Apply other viscoelastic models and compare the die lip profiles between different models Optimize a viscoelastic model for Styron663 with Sintillator dopants

27. www.kostic.niu.edu/extrusion ACKNOWLEDGEMENTS NICADD (Northern Illinois Centre for Accelerator and Detector Development), NIU Fermi National Accelerator Laboratory, Batavia, IL NIU’s College of Engineering and Department of Mechanical Engineering

28. www.kostic.niu.edu/extrusion QUESTIONS ?

29. www.kostic.niu.edu/extrusion Contact Information Mail to: [email protected] www.kostic.niu.edu Mail to: [email protected]

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