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Introduction to VEL
Profile Products
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Introduction
> Polymer (Plastic) processing
Traditionally, development is a black box and like an art.
Extruder
Injection molding
MANDREL
BODY
Extrusion
Others
Blow molding
Others
Thermoforming
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Profiles, pipes
Round products
Flat products
Experiments on a physical extrusion line can
help us to understand the process better
But
- to see what is happening inside the
equipment is very difficult or impossible
- not all variables can be measured
- to study the effects of equipment
modifications is difficult and expensive
Extrusion Equipment
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Extrusion
Profiles, pipes
Round products
Flat products
in which the material is:
- melted & pumped (Extruder)
- shaped (Dies)
- cooled (Cooling systems)
- pulled - off
During the processing, some problems
can occur such as material degradation.
a continuous process
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Virtual Extrusion Laboratory
applications (VEL)
VEL Products V6.5
Extrusion Applications
Extruder module
Flat die module
Multi-Layer module
2D FEM module
3D FEM module
Profile Module

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Compuplast
Virtual Extrusion Laboratory
> Benefits of virtual experiments (Simulations):
detailed information
quantifiable effects of changes
fast response and immediate feedback
lower cost of experiments
no risk of equipment damage
significance of variables
minimize number of physical experiments
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Profile Die Module
> The VEL, Profile Die module features:
improved graphical design interface
local mass throughput/area integration
'slip at the wall' boundary condition
improved image/results saving capability
improved Material Database interface
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There is an infinite number of profile shapes
Profile Dies
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The problem is unbalanced flows (material swell
cannot compensate the unbalancing)
Aim
Reality
Profile Dies
Common Problem in Profile Extrusion
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Velocity
Shear stress
Expected high swell
Many people believe that the swell can balance
an unbalanced flow.
Extrudate swell
Unbalanced Velocities
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The material will not swell, it will bend and wave because
this needs less energy.
Extrudate swell
Profiles, Unbalanced Velocities
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The desired final profile shape must be used for
balancing.
Aim
The profile deformation outside the die is usually
nearly isotropic in width and thickness
Profile Dies Profile Dies
Flow Balancing Flow Balancing Method Method
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This lead to development of the COMPUPLAST

Cross-Flow Minimization Method (CFMM)

Die Design Approach
> Potentially infinite possible ways of designing the profile
> Must consider efficient design procedure and
manufacturing method
> Undesired cross-flows should be eliminated
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Cross-Flow Minimization Method
> Based on forming logical flow patterns
> Directing the proper amount of material to each area of
the die
> Minimizing undesired cross-flows or material
redistribution
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Unbalanced Design
HIGH FLOW AREA
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HIGH FLOW AREA
Unbalance Design
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Balanced Profile
Flow restrictions
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Case Study
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Simple Part Shape
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Die Exit Shape
> Before the procedure can be applied, the basic shape of
the profile at the exit of the die must be specified.
> This shape is determined by considering the material,
draw down, cooling/calibrator design and ease of
operation
This is were experience can help!
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Lofted Shape
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Lofted Shape
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Add Cutting Planes for Plates
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Front and rear view of die plates
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Unbalanced Flow Sections
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Unbalanced Flow Sections
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Flow Balancing
> The next step is the balance the flow in each cross
section using the VEL Profile Die Module.
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Required Part Shape
20%
20%
60%
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Unbalanced Flow Analysis
Insufficient Flow in
these channels
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Original Die Design
Production Rate Limited to 1 m/min !
Die developed using a linear transition from the circular adapter
to the required final shape and cut with via wire EDM.
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Initial Plate Cross Sections
Simulation indicates unbalanced flows
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Balancing of the Die Cross-Section
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Balancing of First Cross Section
Unbalanced Balanced
20%
20%
8%
8%
84% 60%
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Unbalanced Balanced
20%
20%
Balancing of First Cross Section
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Unbalanced Balanced
20%
20%
Balancing of First Cross Section
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Unbalanced Balanced
40%
60%
Balancing of First Cross Section
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Balanced Cross Sections
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This is total die pressure
drop generated on the die
Result Pressure Drop
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Balanced Cross Sections
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Balanced Sections Exported/Imported
to CAD & Lofted
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Balanced Flow Field
The die land length is
sized to give the majority
(50 75%) of the total die
pressure drop
The die land
cross-section is
normally uniform
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Concluding Remarks
> Original cross section shape had poor flow balancing
and restricted line speed to about 1 m/min before part
was out of tolerance.
> Additional time required to balance the 4 cross sections
was about 6 hours
> Balancing the cross sections allowed the line speed to
increase to over 4 m/min.
400% Increase in production rate with
a 6 hour time investment !
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VEL Polyflow
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Polyflow
> POLYFLOW:
POLYFLOW:POLYMAT; POLYDATE;
POLYSTATE,POLYMAN
POLYFLOW
POLYFLOW
,
POLYFLOWGAMBITIDEASPATRAN,
,POLYFLOWGAMBIT
POLYFLOW
POLYFLOWflpost, FieldView,
OEM.
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VEL
> VEL
VELCompuPlast

VEL

VEL

VEL

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VEL
Geometry Setting Project Setting
Material Selection
Results

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VEL Polyflow









CAD


Model

Model













VEL

-FieldView
Polyflow

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> Polyflow

> VEL

> VEL


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