Example 10

EXAMPLE 10
3-D EXTRUSION

DESCRIPTION

In this example we simulate the extrusion process of a simple extrusion profile as can be
encountered in the plastic or rubber industry. We focus on the tools used for solving 3-D
calculations involving a moving domain; hence, we consider a Newtonian fluid model, the
viscosity of which is 10000 Pa.s and the density is 950 kg/m3. In Fig. 1, we display the flow
geometry and the boundary conditions. The fluid enters at the top of the flow domain at a
mass flow rate Q = 0.015 kg/s. It is assumed that it sticks along the wall in the die region. We
have an extrudate jet at the exit of the die, and free surface conditions apply: the shape of the
free surface is a priori unknown. The present computational domain involve two planes of
symmetry.

Fig. 1. 3-D extrusion flow problem: flow geometry and boundary conditions

In this example, we focus on the description of a 3-D problem including boundary conditions
such as inflow (with computation of the fully developed velocity distribution), free surfaces,
plane of symmetry, etc. Together with the free surface boundary conditions, we introduce the
concept of fixed and moving subdomains for a 3-D case. We describe how to define a
remeshing technique for 3-D free surfaces.

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The topology and the finite element mesh are given in Fig. 2. We see that two subdomains are
defined, since the computational domain involves a fixed and a moving part; respectively
referred to as DIE and EXTRUDATE. Also, six boundary sides are defined: successively with
rather explicit names: INLET, WALL, FREE_SURFACE, SYMMETRY1, SYMMETRY2 and
EXIT.

Fig. 2. 3-D extrusion: topology (left) and two views of the finite element mesh (right).
The flow geometry is included within the box x = [0, 9], y = [0, 3.5], z = [-70, 50] mm.

KEYWORDS

3-D flow, 3-D free surface, 3-D remeshing (Optimesh), line kinematic condition

FILENAMES

extru3d.mdf, extru3d.msh, extru3d.dat, extru3d.cons

UNITS

MKS.

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NEW CONCEPTS

The major novelty in this example is that it involves a 3-D calculation with all ingredients as
typically encountered in a 3-D simulation of extrusion. Actually, setting-up a 3-D flow case is
performed along the same guidelines as for a 2-D flow case. The program is able to identify
this by considering the geometric dimension in the mesh.

The flow involves a free surface, and a remeshing algorithm has to be applied for relocating
the internal mesh nodes. In most applications of extrusion, a remeshing algorithm based on a
pseudo-energy minimum, also named "Optimesh", appears to be a good choice. This
remeshing techniques assumes that the moving part of the mesh can be sliced along the flow
direction, and that all slices have the same topology.

Together with this technique, a line integration technique is required for the free surface. This
scheme consists of considering a "chain" of mesh segments as a particle trajectory. The mesh
nodes will be relocated according to the free surface equation. This technique is only
applicable for steady-state jet-like flow situations.

POLYDATA SESSION

- Modify the filename syntax: prefix = extru3d

- Read a mesh: extru3d.msh
- Create a new task: 3D, steady-state
- Create a sub-task: Generalised Newtonian isothermal flow. See note 1
Title: 3D-extrusion
Domain of the sub-task: whole mesh
Material data
Constant viscosity: fac = 104
Density: ro = 950
Flow boundary conditions
EXIT: Fn = Fs = 0 See note 4
FREE_SURFACE: Free surface See note 3
Boundary conditions
Position of free surface imposed on WALL
INLET: Inflow: flow rate = 0.015
Method: automatic See note 2
Type: mass flow rate
SYMMETRY1: Plane of symmetry
SYMMETRY2: Plane of symmetry
WALL: Zero wall velocity (Vn = Vs = 0)
Global remeshing See note 5
Creation of a local remeshing
Remeshing domain: EXTRUDATE
Remeshing technique: Optimesh-3D (extrusion only)

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Inlet of the system of planes: intersection with DIE

Outlet of the system of planes: EXIT
Line kinematic condition See note 6
- Outputs
- Default output: CFD-Post
- System of units for CFD-Post: metric_m/kg/s/A+Celsius
- Probe (optional)
probe 1: prefix: extru_1 location: (0.0, 0.0035, -0.07)
probe 2: prefix: extru_2 location: (0.009, 0.0, -0.07)
probe 3: prefix: extru_3 location: (0.003, 0.0035, -0.07)
- Save and Exit
- mesh: extru3d.msh
- dat: extru3d.dat
- result: extru3d.res
- CFD-Post: extru3d.cfx.res

Note 1. Generalised Newtonian isothermal flow

The present problem contains one sub-task, named "3-D extrusion". All the ingredients are
defined along the same guidelines as for 2-D flows. The domain of the sub-task is the whole
mesh. For the material data, we specify a constant viscosity, equal to 10 000 and a constant
density, equal to 950.

Note 4. Inflow at INLET: mass flow rate = 0.015

We select inflow boundary conditions at the side referred to as INLET. The program asks for
the flow rate. In the next menu, on specify the type of flow rate: volumetric or a mass flow
rate. Presently we select a mass flow rate, meaning that the value of the flow rate is given in
[weight unit/time unit]. A non-zero and constant density must be specified by the user when
mass flow rate is selected.

One can also specify the method of computation of the velocity distribution in the inflow
section. Here, we select the automatic method, allowing POLYDATA to select a method for
the user. In this case, the fully developed method will be applied; based on the knowledge
of this flow rate and the material properties, a 2-D fully developed velocity distribution is
computed on the mesh corresponding to the inflow region. The calculation is automatically
performed by means of a finite element technique (channel flow). The solution of this
problem is imposed as a boundary condition for the 3-D flow.

Note 3. Free surface along the side FREE_SURFACE

Although the computational domain exhibits edges along the free surface, it is not necessary
to split it. The free surface will be treated as a unique boundary side. As for 2-D flows, the
free surface equation requires an initial condition, i.e. the attachment line to the die.
Presently, the free surface is attached (fixed) along the intersection with the boundary
referred to as WALL.

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There may be situations where it is needed to split the free surface along the edges. Edges
which are allowed to move in two planes orthogonal to the direction of extrusion. To define
an edge, we simply define more than one free surface, so that nodes belonging to two free
surfaces will naturally have two geometrical degrees of freedom and will be allowed to move
in two directions. Usually, this is also accompanied by a different remeshing technique, such
as the Thompson remeshing technique of the method of planes. It is worth mentioning also
that the line surface kinematic conditions is applicable only with the Optimesh remeshing
technique (see notes 5 and 6).

Note 2. Vanishing normal and tangential forces at the EXIT

This side is the exit. It is reasonable to expect a uniform velocity distribution at the exit; its
value is a priori unknown. More generally, a bulk flow is obtained, and thus no forces are
acting. The selection of vanishing normal and tangential forces is appropriate. In other
situations such as those involving a pulling velocity or force, or a gravity, the corresponding
boundary condition at the exit must be selected accordingly.

Note 5. Global remeshing

The nodes along the free surface will move according to the kinematic equation. A strategy is
also required for relocating the internal mesh nodes. In most extrusion applications, a
remeshing algorithm based on a pseudo-energy minimum, also named "Optimesh", appears
to be the best choice. Presently, the technique is defined on the subdomain referred to as
EXTRUDATE. This remeshing techniques assumes that the moving part of the mesh can be
sliced along the flow direction, and that all slices have the same topology. In order to slice the
domain, both the inlet and the outlet of the system of planes must be specified. In jet-like
extrusion simulations, the inlet and outlet can be easily understood as respectively the first
and last slice that the fluid sees when it flows.

Note 6. Line kinematic condition

Together with this "Optimesh" remeshing technique, a line integration technique is required
for the free surface. This scheme consists of considering a "chain" of mesh segments as a
particle trajectory. The mesh nodes will be relocated according to the free surface equation.
This technique is only applicable for steady-state jet-like flow situations.

RUNNING POLYFLOW

The input files for POLYFLOW are the mesh extru3d.msh and the data file extru3d.dat. The
data file is the standard input for POLYFLOW. The standard output file is the listing where
all information regarding the calculation are mentioned. POLYFLOW generates a result file
for a possible restart and files for graphic post-processing extru3d.cfx.res.

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GRAPHIC POST-PROCESSING

The (deformed) mesh and result files for graphic processing is extru3d.cfx.res. In Fig. 3a, we
display the deformed mesh. In Figs. 3b and 3c, we display contour lines of the velocity
magnitude in both symmetry planes and in the inlet section.

a) b) c)
Fig. 3. 3D extrusion. Deformed mesh (a), Velocity magnitude in both symmetry planes (b),
and at the inlet section (c).

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