06 schuschnigg modern ways of die design in extrusion · pdf fileschuschnigg 2 content die...

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June 11th, 2014 Leoben

Dipl.-Ing. Stephan Schuschnigg

Modern Ways of Die Design in Extrusion

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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 Leobenstephan.schuschnigg@unileoben.ac.at+43/3842/402-3511