Extrusion Simulation and Design of Diesby
L. Reifschneider, A. Pla-Dalmau, V. Rykalin, A. Bross
ANTEC 2004
Northern Illinois Center for Accelerator and Detector Development (NICADD)
Department of Mechanical Engineering
Two K-Tron automated feeders
Gear pump
All dimensions are in cm
Rectangular cross section of 1 cm  2 cm with a circular hole of 1.1 mm diameter at its center, to accommodate wavelength-shifting optical fiber.
ANTEC 2004
Flow and heat transfer Simulation
Integrate the simulation results with the experimental data
Objectives
2. Mesh the geometry
6.Is the solution converged?
Yes
No
5. Solver solves the conservation equations using the specified data and boundary conditions
Modify remeshing techniques, solver methods and/or evolution parameters
Modify the mesh
ANTEC 2004
General Assumptions
and incompressible
Body forces and Inertia effects are negligible in comparison with viscous and pressure forces.
The flow is steady
Specific heat at constant pressure, Cp, and thermal conductivity, k, are constant
ANTEC 2004
Material Data
Carreau-Yasuda Law for viscosity data:
Measured by, Datapoint Labs, NY
NOTE:
ANTEC 2004
200 0C
180 0C
220 0C
ceet: obtained from Dow's Company
ceet: Obtained from Altair's equation
ceet: Styron 663 without additives - obtained recently
ceet: Styron 663 with additives - obtained recently
663_w-o_add180
663_w-o_add200
663_w-o_add220
663_w_add180
663_w_add200
663_w_add220
663
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ANTEC 2004
Section 1
Section 2
Section 3
Die lip
Melt flow
. Inlet (Fully Developed Flow)
4. Free Surface (Fs = 0, Fn = 0, V.n = 0)
. Outlet (Fn = 0, Vs = 0)
1
ANTEC 2004
Windows XP
ANTEC 2004
Die lip
Melt flow
X (mm)
Y (mm)
Desired profile
New sample
Old Sample
Melt flow direction
Exponent of the Carreau-Yasuda model - significant effect
Flow in the die: no re-circulation regions
ANTEC 2004
Include cooling, solidification and thermo-mechanical stresses in and after the calibrator
Radiation heat transfer for free surface flow
Pulling force at the end of the free surface
Nitrogen pressure inside the hole
More non-uniform mesh
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
ANTEC 2004