Automated generation of virtual prototypes for extrusion dies

• Applicants: Professor Dr.-Ing. Peter Köhler; Professor Dr.-Ing. Johannes Karl Wortberg
• Subject Area: Plastics Engineering
• Term: from 2013 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 240302041

The motivation for this research project is the current lack of holistic approaches for the design and manufacturing of extrusion dies. Existing automatisms are limited to the optimization of the geometry of a die which forms out the final product geometry. All other parts of an extrusion die assembly like inlet, pre-distribution and nozzle region are mostly neglected, although they have an influence on the product quality. Because of this reason the aim of this research project is the implementation of a holistic approach for the automatic generation of a virtual prototype of an extrusion die. Besides the fully automated generation of all flow channel geometries under process technology aspects manufacturing knowledge becomes part of the model. In contrast to other projects a 3D-CAD-assembly that is manufacturing ready is used for the whole process. Combined with a consistent 3D-CFD-analysis the complexity of the results will be improved. Additionally the generality and efficiency of the whole optimization process is part of the process.In the second phase of the project, the research is once again composed of three essential key points. With regard to the approach of a holistic 3D CFD simulation an increase in quality of the results is intended. This will be achieved by adding additional factors of influence, such as the effects of the retention time of thermorheological complex materials or the implementation of three-dimensional transient currents, which allow the evaluation of the rinsing capabilities of tool assemblies. Another main focus of the research provides a methodology for the intelligent classification of successfully tested tool variants. This will be achieved by developing appropriate classification attributes for all influencing input parameters and the obtained optimization results, which will allow an easier identification of the correlation between those attributes. Furthermore, an enhancement of the master model variety for relevant tool variants is proposed, so that alternative predistributor variants can be included (in addition to the already examined star predistribution). The third key point will cover the development of new approaches for innovative design details for different components of the tool assembly. The second half of the project will still consider the design methodology of flow channels under both manufacturing and rheological aspects. For local details of the flow system however (for example the feed region of the secondary distribution), a detailed optimization is approached through innovative methods.

• DFG Programme: Research Grants