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Articles & Tech Briefs

Design Optimization
Coupled to Simulation:
Approaching the Ideal
Design of Extrusion Die.

T
he extrusion process is a process in which molten (thermoplastics and rubbers)
polymer is forced through a shaped die using pressure, generated from the
action of screw rotation against barrel wall. Going
through three steps: transport from polymer
from the feed hopper to the extruder outlet; the melting of the
polymer and the mixing during the process to generate a stable
and homogeneous supply of polymer melt at the extruder outlet.
One of the problems encountered in the extrusion of profiles is
unbalanced flow at the die exit, this process is complicated by
the fact that polymers exhibit
different degrees of non-Newtonian
behavior when exposed to
different shear rates in the die
varying cross-section. A fundamental tool for the solution of
this problem are the computational analysis tools that allow
not only the flow balance as the optimization of the design
and the extrusion process.
Optimization is a tool that assists identify the concept optimal
from a number of possible options, or even from an infinite set
of options. It is increasingly applied in industry since it
provides engineers a cheap and flexible means to identify
optimal designs and processes before physical deployment.
Optimization capabilities have also been increasingly
integrated with CAD/CAM/CAE tools, where we can optimize
performances of the design and process while meet all the
design requirements. The economic impact of optimization to troubleshooting design and process
can be significant, especially if the defect is causing very high scrap rates or production
requirements are not being met.

About the Author

Professional with a wide range of experience working
in companies in Brazil and abroad. Solid background in
Extrusion Process, Mechanical Design, Process & Methods
Engineering and CAE Analysis Engineering. Bachelor’s
degree in Mechanical Engineering with MBA in Project
Management and Specialization in Production Engineering.
“I am currently pursuing Master degree in Mechanical
Engineering.”

Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 1
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Rubber Profile Extrusion

E xtrusions
forced
are
through
“extrusion die” of the required
parts
an
requirements. In the case of
rubber extrusion,
material can be extruded
the

cross section under pressure of with a metal insert and

vulcanized. Vulcanization

an extrusion machine or
extruder. Profiles can be
manufacture in different is a chemical process by which zinc oxide is usually added, not
polymers (plastic and rubber), the physical properties of merely as an extender, but to
it manufactured in straight natural or synthetic rubber are improve further the qualities of
lengths or coils depending on improved; finished rubber has the rubber. Anti-oxidants are
size of profile and can be cut to higher tensile strength and also commonly included to
length to suit customer resistance to swelling and retard deterioration caused by
abrasion, and is elastic over a oxygen and ozone.
greater range of temperatures.
In its simplest form,
vulcanization is brought about
by heating rubber with sulfur,
temperatures of about 140°–
180° C are employed, and in
addition to sulfur and
accelerators, carbon black or

Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 2
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Engineering Applications to Design Optimization

D esign optimization is
based on the idea of
exploiting the power of
based optimization
also called “trial
and error
computer simulations and method" can
optimization in the engineering fall short of
design process, nowadays it is identifying the
always looking to optimize
products or processes with the
aim of reducing development
times, improving efficiency
and / or minimizing
manufacturing costs. This is
evidenced both in the design of
a new product and in the
modification of the design of an
existing product, performing
this task is not simple, mainly
due to the large number of optimal design. Being the also use empirical models
options that the designer has at interactions too complex and (based on the results of
his disposal. Often engineering the variables too numerous to experiments). It is also
optimization is done implicitly, intuitively determine the perfectly acceptable for models
using a combination of optimum design. Although to be solved numerically, using
judgment, experience, engineering models are usually for example, the finite element
modeling, opinions of others, physical in nature (based on method.
etc. This type of experience physical principles), we can

Dimensions, Shape or Topology

A
design
pplied optimization
in
(parts
mechanical
and tools)
of optimization techniques are
significant to the point that
their use is currently decisive to
consists in using define the competitiveness of
computational methods to the industries. It is fundamental
obtain the optimum to understand that the impact of
dimensions, shape or topology the use of these techniques is
of the design. The application of the project itself. The weight not limited to the optimization
of these techniques is a step reductions and the increase of of the mechanical design, but
forward in the use of CAE performance of the mechanical extends to the entire production
software for only the analysis projects obtained with the use chain of the company.
Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 3

Computational Fluid Dynamics (CFD)
C
makes
FD is a branch of
fluid mechanics that
use of different
algorithms and numerical
analysis in order to analyze
and solve problems involving
fluid flows. The main focus is
the use of computers and data
modeling in order to simulate
and analyze quick, efficient
simulation of fluid flow and
heat transfer. It can easily
calculate fluid forces and
understand the impact of a
liquid or gas on product
performance. CFD can be a
regular part of your design
process, reducing the need for
Fluid-Structure Interaction (FSI)
S imulation is an essential
tool in the engineering
design. It allows for the quick
evaluation and optimization of
designs, not only for simulation
experts, but for every engineer
in the process. Within this range
of options that this "world of
simulation" offers, we can
highlight the FSI (fluid-
structure interaction) coupling,
that is the interaction of some
movable or deformable
structure with an internal or
surrounding fluid flow. FSI can
be stable or oscillatory. In
oscillatory interactions, the
strain induced in the solid
structure causes it to move such
that the source of strain is
Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes
4
product performance is time
consuming and costly without
some form of simulation tool.
Engineers across a wide range
of industries can benefit from
CFD, Indeed, almost every
design encounters fluid
dynamics at some point,
costly prototypes, eliminating whether heat or liquids,
rework and delays, and saving internal or external.
time and development costs.
The analysis can be very
complex for example,
containing in one calculation
heat transfer, mixing, and
unsteady and compressible
flows. The ability to predict the
impact of such flows on your
of the actual structure. In the
case of the extrusion die this
phenomenon occurs when the
fluid “rubber” exerts on the
structure “strip steel" a
pressure gradient that can
rupture the strip steel during
the extrusion process if the flow
reduced, and the structure is unbalanced flow at the die
returns to its former state only exit.
for the process to repeat. When
a fluid flow encounters a
structure, stresses and strains
are exerted on the solid object,
forces that can lead to
deformations. These
deformations can be quite large
or very small, depending on the
pressure and velocity of the
flow and the material properties
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Optimization of Extrusion Process

I t is important process optimization to adjusting a process so as to optimize some specified set

of parameters without violating some constraint. The most common goals are minimizing cost
and maximizing throughput and/or efficiency. This is one of the major quantitative tools in industrial
decision making. When optimizing a process, the goal is to
maximize one or more of the process specifications, while
keeping all others within their constraints. In the case of
extrusion process this can be done by using simulation tool
and fundamental basic concepts of fluid mechanics;
discovering the main critical activities and bottlenecks, and
acting incisively only on them.

M ass flow rate is simply a measurement of the amount of

mass (weight) passing by a single point over a length of
time. Mass is always conserved, it is not created or destroyed. Therefore,
if material enters a die at 1 kg/s it must leave the die at
1 kg/s also (as long as there are no leaks). However,
the volume flow rate can change and will do so if the
density changes either through a change in pressure
or temperature.

W hen defining indicators that allow the evaluation of project performance and the quality of
their results, companies will have important information that will support the decision-
making process both to correct discrepancies in the current project or even in future projects. The correct
establishment of the indicators, allowing multiple visualizations, comparing the results and demonstrating
the parameters, is a key point for their real analysis by the management of an ideal project and a stable
process.

Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 5
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Optimization of Extrusion Die Design

O ne of the problems
encountered in the
extrusion of profiles is
production process.
The importance of
conceptual, design, plan and
unbalanced flow at the die implement innovative
exit, this process is technologies that enable
complicated by the fact new and competitive
that polymers exhibit products, helping drive
different degrees of business strategic
non-Newtonian priorities through
behavior when innovative practices.
exposed to different Thus, simulation is
shear rates in the die vital for optimization
varying cross-section. of extrusion die design
It causes deformation of with aim to improving
the extrudates at ambient, performance and
breaking of the metal insert efficiency early in the
during the process and this product development cycle also
precludes the material reduce material waste.
transition through stages of

Striving for New Innovations

T he reality of Brazil is
quite
according to CNI (National
different,

Confederation of Industry)
research, the use of digital
technologies in Brazilian
industry is not widespread. Of
the total industries, 58% are
aware of the importance of
these technologies to industry
competitiveness and less than
half use them.
The advance of Industry
4.0 in Brazil depends on the
companies' knowledge of the
gains of the digitization
(automation, optimization,
others) with respect to the
Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 6
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increase of productivity as well industrial facilities, used in the Advances in computer

as the opportunities of new equipment that make up the graphics technology and
business models, flexibilization extrusion line. information systems make it
and customization of the possible to create an integrated
production in addition to the system that covers the entire
reduction of product launch
time in the market. However, in
the case of the development of
extrusion tooling new
technologies are little explored,
Modular Automation System - Extrusion
even today the old intuitive
concept of “trial and error” in
the elaboration of extrusion
tools is used. This concept that
has been "efficient” for decades
and one of the pillars of development cycle on the same
extrusion industry today it is platform.
outdated and unproductive. Laser Profile Measurement
The process of searching for
Within the technologies
technology and innovation must
researched, companies in the
be part of a company's
segment of polymer extrusion
planning, investing in research
already have technologies and
and new technologies improves
systems of automation that
the quality of its product /
integrates systems and provides
process. In this way companies
the real management of
can use various resources to
generate their own technology,
in other words, an innovation.
Optical Inspection Systems

High Resolution 3D Surface Digitizer

Design Optimization Coupled to Simulation: Approaching the Ideal Design of Extrusion Die; by Eng. Marcelo P. Moraes 7