06 schuschnigg modern ways of die design in extrusion · pdf fileschuschnigg 2 content die...
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Otto Glöckel-Straße 2, A-8700 Leoben, Tel.: +43 3842 402 [email protected]
www.kunststofftechnik.at
June 11th, 2014 Leoben
Dipl.-Ing. Stephan Schuschnigg
Modern Ways of Die Design in Extrusion
Schuschnigg 2
Content
Die & Die Design
Material Data
Calculation
Conductance
Finite Differences
3D –FEM
Challenges in the Future
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Dies
Film and SheetFlat Dies
Rauwendaal, C.: Polymer Extrusion, 5, Hanser Verlag, München, 2014
Moebius manifold
Hennigs, M.; Schippers, S.: A Sector with Plenty of Potential, Kunststoffe International, 1, 21–25, 2014
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Dies
ProfileNon-uniform
Core support dieHensen F., Knappe W., Potente H., Handbuch der Kunststoff- Extrusionstechnik. - 1, Hanser, München, 1989
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Dies
Annular DiesPipes and Tubing
Blow Film
Disk spiral manifold
Spiral manifoldHensen F., Knappe W., Potente H., Handbuch der Kunststoff- Extrusionstechnik. - 1, Hanser, München, 1989
Burmann, G.; Fischer, P.; Wortberg, J.: Schmelzeflussim Circularverteiler, Kunststoffe, 9, 2010
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Coextrusion
Gupta, M.: Three dimensional simulation of coextrusion in a complex profile die, Antec, USA , 2010.
Fröhlich, J.; et al.: Innovative Process Cost Optimization, Kunststoffe International, 12, 32–35, 2012
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Challenges
Materials
New
Other formulation
Costs
Energy costs
Smaller batches
Higher output, more cooling length
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Mass Flow
Die Design
Geometry
Die design ExtruderRheology
Flow Channel
Analytic Calculation
Analysis of Errors
Pressure Drop
Velocities
Numerical Simulations
TemperatureDie
DieMaterial
Shrinkage
Construction
Assembly
Temperature Control
Manufacturing technique
CAD/CAM
ERPTechnical approval
Material
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Material Data
Precision of the calculationsRealistic modelsGood knowledge of the material(T, , p), (T, p), (T, p), cp(T)
Simulation
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Rheological Measuring System
1E+0
1E+1
1E+2
1E+3
1E+4
1E-1 1E+0 1E+1 1E+2 1E+3 1E+4 1E+5
Frequency in rad/s = Shear rate in s-1
Vis
cosi
ty i
n P
a·s
RMS800, Stationary Shearing
RMS800, Dynamic OscillationHigh Pressure Capillary
Material: PP PT55M =200°C
Approximation with the Carreau Model
Dynamic Oscillation
High Pressure Capillary
Stationary Shearing
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Melt Flow Rate
Used for receiving inspectionForce over the time is constant
(HPCR: Velocity is constant)Extrusion time 10 minOne-point measurement
Cylinder: Diameter 9.55 mm Length >115 mm
Die Diameter 2.095 mm Length 8 mm
Die
Cutter
Piston Weight
Cylinder
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MFR for Comparison
MFR A= MFI B= 5 g/10 minViscosity not identical!
MFR
log
log
Ticona Hostaform S9363 Ticona Celcon M50-14
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Simulation Injection Moulding
Hostaform S9363 Celcon M50-1425%
Lucysyhn
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Influence on the Stream Function
Dissipative heating
Influence of the shear history
Slip-Stick effect
Wall slipping
Die swell
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Conductance
Volume rate dependency of the pressure for a pseudo plastic fluid
n1
DL
n1 pK
k
1V
n1
n1
nn31
DL
L
1
n312
nRK
Circular die
Hensen, F., Knappe, W., Potente, H.: Handbuch der Kunststoff-Extrusionstechnik I, Hanser Verlag, Wien München, 1989Michaeli, W.: Extrusionswerkzeuge, Carl Hanser Verlag, Wien München, 1979
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Finite Differences
Method for solving partial differential equations Replacing the continuum with a finite difference meshSolving the linearized equation in small steps
Pure shear flow
Pure wall slip
zHB
12Vp 3
HB
zHB2HBK
Vpvn1
v
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3D-FEM
Complex geometries
Coupled problems
Highly non-linear solutions
Results
Pressure
Temperature
Velocities
Die swellCompuplast® Virtual Extrusion LaboratoryTM
Balanced
Not balanced
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Results for a Rectangular Die
18
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Challenges in the Future
Viscoelastic calculations
Die swell
Inverse extrusion
Interlaminar behaviour
Better Understanding of the Mixing
Dispersive
Distributive
Molecular basis
Open Foam
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THANK YOU FOR THE ATTENTION!
Dipl.-Ing. Stephan SchuschniggFranz Josef Straße 18, 8700 [email protected]+43/3842/402-3511