Effect of Die Lip Geometry on Polymer Extrudate Deformation in Complex Small Profile Extrusion

2017 ◽  
Vol 139 (6) ◽  
Author(s):  
Huiqing Tian ◽  
Danyang Zhao ◽  
Minjie Wang ◽  
Yifei Jin
Keyword(s):  
Three Dimensional ◽  
Polymer Melt ◽  
Quantitative Agreement ◽  
Geometric Parameters ◽  
Die Design ◽  
Wall Region ◽  
Thin Wall ◽  
Minor Variation ◽  
Global Deformation ◽  
A Minor

The extrusion of polymer profile products with complex microcross section is difficult due to the extrudate deformation, especially for the profile with multihollow lumens and inner ribs. In order to investigate the effect of die lip geometry on extrudate deformations, three-dimensional simulations have been undertaken for typical small profile extrusions both inside and outside the die using finite-element method (FEM). The Carreau model was used to describe the shear-thinning behavior of polymer melt. The systematic definitions of the die lip geometric parameters and evaluations of the extrudate deformations were proposed. It was found that the thickness and profile deformations happen asynchronously, and the existence of the inner rib changes the global deformation, which cannot be predicted by a deformation combination of the basic geometries. Among the investigated die lip geometric parameters, the wall thickness ratio has the most pronounced effect on both thickness and external profile deformations of the extrudates, with the maximum variation of more than 80%. The decrease of the hollow ratio significantly reduces the extrudate deformation extent, especially the extrudate external profile and the extrudate thickness of the thin-wall region. Even with uniform thickness, the location and shape of the inner rib also generate extrudate deformations not only on the inner rib but also on the thickness of the outer ring at the region not connected with it, by a minor variation level of 5–25%. Comprehensive understandings on the mechanism of extrudate deformations and effects of die lip geometry were obtained. Some hints for small profile die design were provided accordingly. Numerical results showed qualitative and quantitative agreement with the experiments.

scholarly journals Lath Martensite Microstructure Modeling: A High-Resolution Crystal Plasticity Simulation Study

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 691
Author(s):  
Francisco-José Gallardo-Basile ◽  
Yannick Naunheim ◽  
Franz Roters ◽  
Martin Diehl
Keyword(s):  
High Resolution ◽  
Mechanical Behavior ◽  
Crystal Plasticity ◽  
Lath Martensite ◽  
Three Dimensional ◽  
Building Blocks ◽  
Quantitative Agreement ◽  
Carbon Steels ◽  
Plastic Behavior ◽  
Austenitic Phase

Lath martensite is a complex hierarchical compound structure that forms during rapid cooling of carbon steels from the austenitic phase. At the smallest, i.e., ‘single crystal’ scale, individual, elongated domains, form the elemental microstructural building blocks: the name-giving laths. Several laths of nearly identical crystallographic orientation are grouped together to blocks, in which–depending on the exact material characteristics–clearly distinguishable subblocks might be observed. Several blocks with the same habit plane together form a packet of which typically three to four together finally make up the former parent austenitic grain. Here, a fully parametrized approach is presented which converts an austenitic polycrystal representation into martensitic microstructures incorporating all these details. Two-dimensional (2D) and three-dimensional (3D) Representative Volume Elements (RVEs) are generated based on prior austenite microstructure reconstructed from a 2D experimental martensitic microstructure. The RVEs are used for high-resolution crystal plasticity simulations with a fast spectral method-based solver and a phenomenological constitutive description. The comparison of the results obtained from the 2D experimental microstructure and the 2D RVEs reveals a high quantitative agreement. The stress and strain distributions and their characteristics change significantly if 3D microstructures are used. Further simulations are conducted to systematically investigate the influence of microstructural parameters, such as lath aspect ratio, lath volume, subblock thickness, orientation scatter, and prior austenitic grain shape on the global and local mechanical behavior. These microstructural features happen to change the local mechanical behavior, whereas the average stress–strain response is not significantly altered. Correlations between the microstructure and the plastic behavior are established.

scholarly journals Visualization of the Strain-Rate State of a Data Cloud: Analysis of the Temporal Change of an Urban Multivariate Description

2019 ◽  
Vol 9 (14) ◽  
pp. 2920
Author(s):  
Lorena Salazar-Llano ◽  
Camilo Bayona-Roa
Keyword(s):  
Strain Rate ◽  
Temporal Change ◽  
Three Dimensional ◽  
Urban System ◽  
Deformation Pattern ◽  
Analysis Methodology ◽  
Global Deformation ◽  
Temporal Rate ◽  
Cloud Of Points ◽  
Entire Dataset

One challenging problem is the representation of three-dimensional datasets that vary with time. These datasets can be thought of as a cloud of points that gradually deforms. However, point-wise variations lack information about the overall deformation pattern, and, more importantly, about the extreme deformation locations inside the cloud. This present article applies a technique in computational mechanics to derive the strain-rate state of a time-dependent and three-dimensional data distribution, by which one can characterize its main trends of shift. Indeed, the tensorial analysis methodology is able to determine the global deformation rates in the entire dataset. With the use of this technique, one can characterize the significant fluctuations in a reduced multivariate description of an urban system and identify the possible causes of those changes: calculating the strain-rate state of a PCA-based multivariate description of an urban system, we are able to describe the clustering and divergence patterns between the districts of a city and to characterize the temporal rate in which those variations happen.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

scholarly journals Flexible Die Design and Springback Compensation Based on Modified Displacement Adjustment Method

2014 ◽  
Vol 6 ◽  
pp. 131253 ◽  
Author(s):  
Young-Ho Seo ◽  
Ji-Woo Park ◽  
Woo-Jin Song ◽  
Beom-Soo Kang ◽  
Jeong Kim
Keyword(s):  
Closed Loop ◽  
Three Dimensional ◽  
Loop System ◽  
Die Design ◽  
Manufacturing Cost ◽  
Closed Loop System ◽  
Forming Process ◽  
Element Analysis ◽  
Springback Compensation ◽  
Flexible Die

Springback in metal forming process often results in undesirable shape changes in formed parts and leads to deterioration in product quality. Even though springback can be predicted and compensated for through the theories or methodologies established thus far, an increase in manufacturing cost accompanied by a change in die shape is inevitable. In the present paper, it is suggested that the cost accompanied with springback compensation can be minimized while allowing the processing of various three-dimensional curved surfaces by using a flexible die composed of multiple punches. With the die being very flexible, the iterative trial-and-error method can be readily applied to compensate for the springback. Thus, repeated designing and redesigning of solid or matched dies can be avoided, effectively saving considerable time. Only some adjustments of punch height are required. Detailed designs of the flexible die as well as two core algorithms to control the respective punch heights are described in this paper. In addition, a closed-loop system for the springback compensation using the flexible die is proposed. The amount of springback was simulated by a finite element analysis and the modified displacement adjustment (DA) method as the springback compensation model was used in the closed-loop system. This system was applied to a two-dimensional quadratic shape problem, and its robustness was verified by an experiment.

The Influence of Static Response of Super Tall Building Mega-Frame Structure Caused by Changes of Frame Rigidities

2012 ◽  
Vol 166-169 ◽  
pp. 277-281
Author(s):  
Xiang Dong Xie ◽  
Xuan Wang ◽  
Li Qin
Keyword(s):  
Differential Equation ◽  
Analytical Approach ◽  
Three Dimensional ◽  
Tall Building ◽  
Frame Structure ◽  
Thin Wall ◽  
Static Response ◽  
Dimensional Model ◽  
Three Dimensional Model ◽  
Frame Rigidity

The superstructure and its foundation of a super tall building mega-frame structure are simplified equivalently and continuously to a stiffened-thin-wall tube on semi-infinite elastic subgrade. And the influences of static response on super tall building mega-frame structure caused by changes of frame rigidity are computed and analyzed with the three-dimensional model by semi-analytical approach based on ODE(Ordinary Differential Equation) Solver, considering the interactions of subgrade, foundation and superstructure. Then some valuable conclusions are obtained through analyzing the reasonable results of the numerical example.

Thermocapillary Convection With Undeformable Curved Surfaces in Open Cylinders

2001 ◽  
Author(s):  
Bok-Cheol Sim ◽  
Abdelfattah Zebib
Keyword(s):  
Free Surface ◽  
Critical Frequency ◽  
Thermocapillary Convection ◽  
Three Dimensional ◽  
Quantitative Agreement ◽  
Fluid Volume ◽  
Uniform Heat Flux ◽  
Free Surfaces ◽  
Space Experiments ◽  
Steady Convection

Abstract Thermocapillary convection driven by a uniform heat flux in an open cylindrical container of unit aspect ratio is investigated by two- and three-dimensional numerical simulations. The undeformable free surface is either flat or curved as determined by the fluid volume (V ≤ 1) and the Young-Laplace equation. Convection is steady and axisymmetric at sufficiently low values of the Reynolds number (Re) with either flat or curved interfaces. Only steady convection is possible in strictly axisymmetric computations. Transition to oscillatory three-dimensional motions occurs as Re increases beyond a critical value dependent on Pr and V. With a flat free surface (V = 1), two-lobed pulsating waves are found on the free surface and prevail with increasing Re. While the critical Re increases with increasing Pr, the critical frequency decreases. In the case of a concave surface, four azimuthal waves are found rotating clockwise on the surface. The critical Re decreases with increasing fluid volume, and the critical frequency is found to increase. The numerical results with either flat or curved free surfaces are in good quantitative agreement with space experiments.

Effect of Material and Geometric Parameters on the Steady-State Belt Stresses and Belt Slip for Flat Belt-Drives

2015 ◽  
Author(s):  
Cagkan Yildiz ◽  
Tamer M. Wasfy ◽  
Hatem M. Wasfy ◽  
Jeanne M. Peters
Keyword(s):  
Steady State ◽  
Equations Of Motion ◽  
Three Dimensional ◽  
Flexible Multibody Dynamics ◽  
Friction Model ◽  
Rigid Bodies ◽  
Geometric Parameters ◽  
Rubber Matrix ◽  
Axial Stiffness ◽  
Belt Drive

In order to accurately predict the fatigue life and wear life of a belt, the various stresses that the belt is subjected to and the belt slip over the pulleys must be accurately calculated. In this paper, the effect of material and geometric parameters on the steady-state stresses (including normal, tangential and axial stresses), average belt slip for a flat belt, and belt-drive energy efficiency is studied using a high-fidelity flexible multibody dynamics model of the belt-drive. The belt’s rubber matrix is modeled using three-dimensional brick elements and the belt’s reinforcements are modeled using one dimensional truss elements. Friction between the belt and the pulleys is modeled using an asperity-based Coulomb friction model. The pulleys are modeled as cylindrical rigid bodies. The equations of motion are integrated using a time-accurate explicit solution procedure. The material parameters studied are the belt-pulley friction coefficient and the belt axial stiffness and damping. The geometric parameters studied are the belt thickness and the pulleys’ centers distance.

Design Optimization of an L-Shaped Extrusion Die

2009 ◽  
Author(s):  
Oktay Yilmaz ◽  
Hasan Gunes ◽  
Kadir Kirkkopru
Keyword(s):  
Simulated Annealing ◽  
Optimization Problem ◽  
Numerical Solutions ◽  
Latin Hypercube Sampling ◽  
Kriging Model ◽  
Narrow Channel ◽  
Geometric Parameters ◽  
Die Design ◽  
Dimensional Parameter ◽  
Large Channel

It is an important problem in the polymer extrusion of complex profiles to balance the flow at the die exit. In this paper, we employ simulated annealing-kriging meta-algorithm to optimize the geometric parameters of a die channel to obtain a uniform exit velocity distribution. Design variables for our optimization problem involve the suitable geometric parameters for the die design, which are the thickness of the large channel and the length of the narrow channel. Die balance is based on the deviation of the velocity with respect to the average velocity at the die exit. So the cost function for the optimization problem involves the minimization of this deviation. For the design of numerical experiments, we use Latin Hypercube Sampling (LHS) to construct the kriging model. Then, based on the LHS points, the numerical solutions are performed using Polyflow, a commercial software based on the finite element method and is specifically designed to simulate the flow and heat transfer of non-newtonian, viscoelastic fluids. In our simulations, a HDPE (high density polyethylene) is used as extrusion material. Having obtained numerical simulations for N = 60 LHS points in two-dimensional parameter space (t and L), the optimization of these parameters is carried out by Simulated Annealing (SA) method in conjunction with kriging model. We show that kriging model employed in SA algorithm can be used to optimize the die geometry.

Calculation of Developing Turbulent Flows in a Rotating Pipe

1991 ◽  
Vol 113 (1) ◽  
pp. 34-41 ◽  
Author(s):  
G. J. Yoo ◽  
R. M. C. So ◽  
B. C. Hwang
Keyword(s):  
Turbulent Flows ◽  
Reynolds Stress ◽  
Circumferential Strain ◽  
Three Dimensional ◽  
Wall Region ◽  
Boundary Layer Flows ◽  
Viscous Effects ◽  
Wide Range ◽  
Turbulence Closures ◽  
Rotating Boundary

Internal rotating boundary-layer flows are strongly influenced by large circumferential strain and the turbulence field is anisotropic. This is especially true in the entry region of a rotating pipe where the flow is three dimensional, the centrifugal force due to fluid rotation is less important, and the circumferential strain created by surface rotation has a significant effect on the turbulence field near the wall. Consequently, viscous effects cannot be neglected in the near-wall region. Several low-Reynolds-number turbulence closures are proposed for the calculation of developing rotating pipe flows. Some are two-equation closures with and without algebraic stress correction, while others are full Reynolds-stress closures. It is found that two-equation closures with and without algebraic stress correction are totally inadequate for this three-dimensional flow, while Reynolds-stress closures give results that are in good agreement with measurements over a wide range of rotation numbers.

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