Incorporating Adjustable Features in the Optimal Design of Polymer Sheet Extrusion Dies

[+] Author and Article Information
Douglas E. Smith1

Department of Mechanical and Aerospace Engineering, University of Missouri - Columbia, E2411 Engineering Building East, Columbia, MO 65211

Qi Wang

Department of Mechanical and Aerospace Engineering, University of Missouri - Columbia, E2411 Engineering Building East, Columbia, MO 65211


E-mail: smithdoug@Missouri.edu

J. Manuf. Sci. Eng 128(1), 11-19 (Jun 23, 2005) (9 pages) doi:10.1115/1.2113027 History: Received August 02, 2004; Revised June 23, 2005

It is common for materials processing operations to have adjustable features that may be used to improve the quality of the final product when variability in operating conditions is encountered. This paper considers the polymer sheeting die design problem where variability in operating temperature or material properties, for example, requires that the die be designed to perform well under multiple operating conditions. An optimization procedure is presented where the design variables parametrize both stationary and adjustable model variables. In this approach, adjustable features of the die cavity are modified in an optimal manner consistent with the overall design objectives. The computational design approach incorporates finite element simulations based on the Generalized Hele-Shaw approximation to evaluate the die’s performance measures, and includes a gradient-based optimization algorithm and analytical design sensitivities to update the die’s geometry. Examples are provided to illustrate the design methodology where die cavities are designed to accommodate multiple materials, multiple flow rates, and various temperatures. This paper demonstrates that improved tooling designs may be computed with an optimization-based process design approach that incorporates the effect of adjustable features.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Coat hanger die geometry with fixed and adjustable (i.e., choker bar) regions

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Figure 2

Viscosity as a function of shear rate for LDPE at various temperatures (7)

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Figure 3

Coat hanger die cavity geometry

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Figure 4

Initial die cavity half-heights for multiple operating condition optimizations

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Figure 5

Percent change in die cavity half-height between initial and optimal designs for LDPE multiple operating temperature optimization [half-height shown for q=2 (i.e., LDPE at 453 K)]

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Figure 6

Die cavity half-heights in the manifold flow channel and the preland for LDPE multiple operating temperature optimization

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Figure 7

Choker bar half-height across die for optimal design in LDPE multiple temperature die design

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Figure 8

Exit velocities for LDPE multiple temperature die design



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