Extrusion Simulation and Optimization of Profile Die Design

03-25-2003

By

Srinivasa Rao Vaddiraju

Advisor

Prof. Milivoje Kostic

Introduction
Extrusion describes the process by which a polymer melt is pushed across a metal die, which continuously shapes the melt into the desired form.
Polymer pellets Dopants Feeding

r e yr D

Hopper

Breaker plate Die Gear pump Calibrator

Cooling

Haul-off Cutter

Extruder

Measurement

A Schematic of Profile Extrusion Line at FNAL

Quality factors
Extrudate swell
rearrangement of the velocity profile as the polymer leaves the die

Draw down Cooling Insufficient mixing in the extruder Uneven die body temperatures and raw material variations Non-uniform viscosity in the die Non-uniform swelling Non-uniform draw down

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate. Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain. Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate. Prepare the complete design of dies, including blue prints.

Objectives An attempt to develop a possible strategy for effective die design in profile extrusion
Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate. Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain. Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate. Prepare the complete design of dies, including blue prints.

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion

Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.
Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the freeflow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain. Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate. Prepare the complete design of dies, including blue prints.

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate.

Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.
Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain. Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate. Prepare the complete design of dies, including blue prints.

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profile-shape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate. Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc.

Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.
Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate. Prepare the complete design of dies, including blue prints.

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profileshape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate. Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain.

Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.
Prepare the complete design of dies, including blue prints.

Objectives
An attempt to develop a possible strategy for effective die design in profile extrusion Investigate the die swell behavior of the polymer and to predict the optimum die profileshape and dimensions, including the pin(s) profile, to obtain the required dimensions and quality of the extrudate. Investigate the swell phenomenon and mass flow balance affected by different parameters like die lengths, flow rates, exponent in viscosity function etc. Simulate the flow and heat transfer of molten polymer inside the die and in the free-flow region after the die exit, and compute pressure, temperature, velocity, stress and strain rate distributions over the entire simulation domain. Investigate and understand over-all polymer extrusion process, and integrate the simulation results with the experimental data, to optimize the die design and ultimately to achieve better quality and dimensions of the extrudate.

Prepare the complete design of dies, including blue prints.

Design Methodology
Using Finite Element based CFD code Polyflow Using the method of Inverse Extrusion To fully understand the extrusion processes and the influence of various parameters on the quality of the final product. Integrate the simulation results and the experimental data to obtain more precise extrudate shape.

Literature Review
The text book Dynamics of Polymeric Liquids by R.B.Bird gives a detailed overview of non-Newtonian fluid dynamics, which is important to understand the flow of polymers. The text book Extrusion Dies by Walter Michaeli gives an extensive representation of extrusion processes and guidelines for the design of dies. The text book Plastics Extrusion Technology Handbook by Levis gives a clear representation of the rheology of materials and the technology of extrusion processes. Woei-Shyong Lee and Sherry Hsueh-Yu Ho have investigated the die swell behavior of a polymer melt using finite element method and simulated flow of Newtonian fluid and designed a profile extrusion die with a geometry of a quarter ring profile Louis G. Reifschneider has designed a coat hanger extrusion die using a parametric based three-dimensional polymer flow simulation algorithm, where the shape of the manifold and land are modified to minimize the velocity variation across the die exit. W.A. Gifford has demonstrated through an actual example how the efficient use of 3-D CFD algorithms and automatic finite element mesh generators can be used to eliminate much of the cut and try from profile die design.

Governing Equations
Continuity Equation Momentum Equation
( vx ) + (v y ) + ( vz ) = 0 x y z

Where,

P is the pressure, is the extra stress tensor, v is the velocity.

P zx zy zz = + + z x y z

P xx xy xz = + + x x y z P yx yy yz = + + y x y z

Energy Equation E acc + E conv = E cond + E diss

T E acc = C v the accumulation term, t T T T + vy + vz the convection term, E conv = C v v x x y z T T T Econd = k + k the conduction term, y + z k z x x y
the dissipation term,

= v x + v y + v z + v x + v y Ediss xx yy zz xy y x x y z v y v z v x v z + xz + + yz z + y z x

Where,

Cv is the specific heat capacity of the material, T is the temperature, is the density, k is the thermal conductivity.

Die Design
The art of die design is to predict properly irregular die shape (with minimum number of trials) which will allow melt flow to reshape and solidify into desired (regular) extrudate profile. The correct geometry of the die cannot be completely determined from engineering calculations. Numerical methods

POLYFLOW
Finite-element CFD code Predict three-dimensional free surfaces Inverse extrusion capability Strong non-linearities Evolution procedure

Flowchart for numerical simulation using Polyflow

1. Draw the geometry in Pro-E (or) other CAD software and export to GAMBIT 2. Draw the geometry in GAMBIT (or) import from other CAD software and mesh it. Modify the mesh Change the remeshing techniques and/or solver methods Modify the evolution parameters No 3. Specify Polymer properties in Polydata 4. Specify boundary conditions in Polydata 5. Specify remeshing technique and solver method in Polydata 6. Specify the evolution parameters in Polydata 7. Polyflow solves the conservation equations using the specified data and boundary conditions 8.Is the solution converged? Yes Stop

General Assumptions
The flow is steady
0 t

and incompressible v = 0 Body forces and Inertia effects are negligible in comparison with viscous and pressure forces. Specific heat at constant pressure, Cp, and thermal conductivity, k, are constant

Boundary Conditions
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C). Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K. Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0. Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation

v .n = 0

on free

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0. All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K. Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0. Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation

Boundary Conditions

v .n = 0

on free

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0. All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary Conditions
Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C).

Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.

v .n = 0

on free

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0. All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary Conditions
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C). Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K.

Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.
Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation

v .n = 0

on free

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0. All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary Conditions
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C). Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K. Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0.

Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding room-temperature air. Kinematic balance equation v .n = 0 on free
Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0. All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary Conditions
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C). Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K. Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0. Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.

v .n = 0

on free

All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Boundary Conditions
Inlet: Fully developed inlet velocity corresponding to actual mass flow rate of 50 kg/hr and uniform inlet temperature (473 K or 200 C). Die, spider and pin walls: No slip at the die walls (Vn =Vs = 0; normal and streamline velocities, respectively), and uniform die wall temperature 473 K. Symmetry planes: Shear stress Fs = 0, normal velocity Vn = 0 and normal heat flux qn =0. Free surface: Zero pressure and traction/shear at boundary (Fn = 0, Fs = 0, and Vn =0), and convection heat transfer from the free surface to surrounding roomtemperature air. Kinematic balance equation

v .n = 0

on free

Outlet: Normal stress Fn =0, Tangential Velocity Vs = 0, Pressure = 0.0 (reference pressure) and normal heat flux qn =0.

All domains: Viscous dissipation was neglected for all flow conditions (after verification).

Material Data
Styron 663, mixed with Scintillator dopants
Carreau-Yasuda Law for viscosity data:
Measured by, Datapoint Labs

= + ( 0 ) 1 + ( )
Zero shear rate viscosity, 0 = 36,580 Pa-s Infinite shear rate viscosity, = 0 Pa-s Natural time, = 0.902 Transition Parameter, a = 0.585 Exponent, n = 0.267 Density, = 1040 Kg/m3 Specific Heat, cp = 1200 J/Kg-K

n 1 a a

Thermal Conductivity, k = 0.12307 W/m-K Coefficient of thermal expansion, = 0.5e-5 m/m-K

Styron viscosity data, with and without Scintillator dopants

106

Styron 663 d Doped Styron 663

180 0C 200 0C 220 0C

Viscosity (Pa-s)

105

104

103

102

10-2

10-1

100

101

102

103

Shear Rate (1/s)

Profiles
Rectangular profile die with one hole Rectangular profile die with ten holes

Rectangular profile die with one hole

0.11

1.0

2.0 Required extrudate is a rectangular cross section of 1 cm 2 cm with a circular hole of 1.1 mm diameter at its center ALL DIMENSIONS ARE IN CM

Sensitivity analysis of die swell and inverse extrusion capabilities of Polyflow

Percentage Differences
Reference Inertia terms not included Exponent in Carreau Yasuda model, n P1(0,y) 0 -0.007% 0.252 0.003% 0.28271 1.495% 0.3522 3.692% 0.453 8.439% 0.5286 11.354% 1.20E+05 0.007% (Pa-s) 1.34E+05 2.00E+05 2.40E+05 2.80E+05 0.006% 0.000% 0.001% 0.000% P5(x,0) 0 -0.001% 0.001% -1.765% -4.583% -11.776% -17.410% 0.002% 0.002% 0.000% 0.002% 0.002% 0.017% 0.014% 0.000% -0.010% -0.016% 0.104% 0.000% 0.020% 0.000% -0.030% -0.042% 1.82% P2(0,y) 0 -0.002% 0.000% 0.646% 1.619% 3.935% 5.718% 0.000% 0.000% 0.000% -0.001% -0.001% 0.232% 0.073% 0.000% -0.069% -0.128% -1.025% 0.000% 0.329% 0.000% -0.182% -0.249% 0.17% P4(x,0) 0 -0.001% 0.000% 0.380% 0.979% 2.521% 3.806% 0.000% 0.000% 0.000% -0.001% -0.001% 0.190% 0.060% 0.000% -0.058% -0.105% -0.701% 0.000% 0.269% 0.000% -0.148% -0.203% 0.04% P3(x) 0 -0.001% 0.000% 0.465% 1.138% 2.686% 3.876% 0.000% 0.000% 0.000% 0.000% -0.001% 0.245% 0.079% 0.000% -0.074% -0.136% -0.932% 0.000% 0.346% 0.000% -0.193% -0.262% 0.3% P3(y) 0 0.002% 0.000% 0.358% 0.864% 1.995% 2.843% -0.001% -0.001% 0.000% 0.001% 0.001% 0.095% 0.030% 0.000% -0.029% -0.054% -0.406% 0.000% 0.133% 0.000% -0.075% -0.102% 0.61%

P2 (0,y)

P3 (x,y)

Zero shear rate viscosity,

P1 (0,y) P5 (x,0)

P4 (x,0)

Flow rate (m /s)

1.54E-05 0.640% 2.15E-05 0.207% 2.58E-05 0.000% 3.04E-05 -0.189% 3.61E-05 -0.352% 2 -2.757% 0.5 0.000% 2.31685 0.914% 4.6337 0.000% 7.53 -0.507% 9.2674 -0.693% -0.18%

Transition Parameter, a Time constant,

Inverse Extrusion

Full domain of the extrusion die

Melt flow direction

Half domain of the extrusion die

Section 3

Melt flow direction

Section 2 Die lip Section 1

Simulation domain with boundary conditions

1. Inlet (Fully Developed Flow) 2. Wall (Vn = 0, Vs = 0) 3. Symmetry (Vn = 0, Fs = 0) 4. Free Surface (Fs = 0, Fn = 0, V.n = 0) 5. Outlet (Fn = 0, Vs = 0)

Finite element 3-D domain and die-lip mesh

30,872 elements Skewness < 0.33

Melt flow direction Die Lip

Windows XP 2.52 GHz Processor 1 GB RAM

19 hours and 36 minutes of CPU time

Contours of static pressure

Melt flow direction

Die lip

Contours of velocity magnitude at different iso-surfaces

Melt flow direction

Die lip

Contours of temperature distribution

Melt flow direction

Die lip

Contours of shear rate

Die lip Melt flow direction

Existing die, corresponding simulation and new improved-die profiles

7 6 5 4 3 2 1 0 0
X (mm) Desired Extrudate Existing-Die Extrudate (Simulated) New Die (Simulated) Existing Die

Y (mm)

10

Exploded view of the extrusion die

2 D-View of the extrusion die

Melt flow direction

Blue prints

Preland

Dieland

Pin

Rectangular profile die with ten holes

0.11 10.0 Required extrudate is a rectangular cross section of 0.5 cm 10 cm with ten equally spaced centerline circular holes of 1.1 mm diameter. ALL DIMENSIONS ARE IN CM

0.5

Full domain of the extrusion die

Melt flow direction

Half domain of the extrusion die

Melt Pump Adapter, Adapter 1 and Adapter 2

Spider

Die land Free Surface Melt flow direction Die lip

Simulation domain with boundary conditions

1 2

4 Melt flow direction 3 1. Inlet (Fully Developed Flow) 2. Wall (Vn = 0, Vs = 0) 3. Symmetry (Vn = 0, Fs = 0) 4. Free Surface (Fs = 0, Fn = 0, V.n = 0) 5. Outlet (Fn = 0, Vs = 0)

Finite element 3-D domain and half of extrudate profile mesh

19,479 elements Skewness < 0.5

Melt flow direction

Half domain of the extrusion die (without free surface) and division of outlet into 10 areas
d2
out8 out10 out9 out7 out6 out5 out4 out3 out2 out1

d0

d1 Melt flow direction

Percentage of Mass flow rate in different exit segments

Out10 Out9 Out8 Out7 C ase 8 C ase C ase C ase C ase C ase 7 6 5 4 3

Outlet

Out6 Out5 Out4 Out3 Out2 Out1 0.00% 5.00% 10.00%

C ase 2 C ase 1

% of mass flow rate

Windows XP 2.52 GHz Processor 1 GB RAM

One hour of CPU time

Contours of Static pressure

Melt flow direction

Die lip

Contours of Velocity magnitude at different isosurfaces and at centerline of exit

Velocity Magnitude (m/s)

X-Coordinate (m)

Melt flow direction Die lip

Contours of Temperature distribution

Melt flow direction Die lip

Contours of Shear rate and Viscosity

Melt flow direction Die lip

Shear rate

Melt flow direction

Viscosity

Simulated die and required extrudate profiles

1 0

24

25

26

27

-1

0 4 5 6 7

0 44 45 46 47

-1

-1

3 0 0 -3
1

10

20

30
1

40

50

Simulated Die Required Extrudate

0 1 4 1 5 1 6 1 7

0 34 35 36 37

-1

-1

Percentage of mass flow rate for designed and balanced die

Designed Die Out10 Out9 Out8 Out7 Out6 Out5 Out4 Out3 Out2 Out1 0.00% 5.00% % of Mass Flow Rate 10.00% Balanced Die

Outlet

Exploded view of the extrusion die

Melt pump adapter Adapter 1 Adapter 2 Preland Dieland

Melt flow direction

Blue prints

Whole die

Melt pump adapter

Adapter 1

Adapter 2

Spider

Die land

Conclusions
The optimum dimensions of the die to attain more balanced flow at the exit were obtained. The effect of inertia terms is found to be negligible for polymer flows at low Reynolds number. The exponent of the Carreau-Yasuda model, or the slope of the viscosity vs shear rate curve, has a significant effect on the die swell. The flow in the die appeared to be smooth with no re-circulation regions.

Recommendations for future improvements

Polymer viscoelastic properties Include flow, cooling, solidification and vacuuming in and after the calibrator Radiation effects for free surface flow Pulling force at the end of the free surface Pressure of the compressed air Non-uniform mesh

ACKNOWLEDGEMENTS
Prof. Milivoje Kostic Prof. Pradip Majumdar Prof. M.J. Kim Prof. Lou Reifschneider NICADD (Northern Illinois Centre for Accelerator and Detector Development), NIU Fermi National Accelerator Laboratory, Batavia, IL

QUESTIONS ?