Shape Optimization for Weight Reduction of Polymer Extrusion Die

Abstract:

Polymer extrusion is one of the most widely utilized manufacturing processes across many industries including automotive, architecture, aerospace etc. However, in order to maintain normal operations, polymer extrusion dies are conventionally designed with large dimensions and thick walls which results in the overweight of them. In this paper, a shape optimization method is proposed to reduce the weight of polymer extrusion dies without sacrificing the required performances of extrudate. Firstly, Finite element simulation of the extrusion process is conducted using the commercial software HyperXtrude to study both the essential flow characteristics of polymer melts and the deformation and stress distribution of extrusion die. Secondly, shape optimization is conducted to find the minimum weight of extrusion die while satisfying the required properties and productivity of polymer product. The extrusion die is then redesigned according to the result of shape optimization and compared with the original one. A Medium-sized polymer profile extrusion die is selected as case study, the result of which shows that the weight of the extrusion die is reduced by 31.6%,though the maximal deformation and stress of the die are increased by 1.7% and 16.1% respectively. The proposed approach is demonstrated to be effective for the lightweight design of polymer extrusion die.

• Periodical: Applied Mechanics and Materials (Volumes 799-800)
• Pages: 261-265
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.799-800.261
• Online since: October 2015
• Authors: Tao Huang, Yan He*, Yi Nie, Yan Wang, Yueh Jaw Lin, Jing Hao
• Keywords: Extrusion Die, Numerical Simulation, Shape Optimization, Weight Reduction

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