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PROGRESS IN ENGINEERING COMPUTATIONAL TECHNOLOGY
Edited by: B.H.V. Topping, C.A. Mota Soares
Simulation and Optimization for Polymer Processing
J. Sienz, J.F.T. Pittman and A. Polynkin
Centre for Polymer Processing Simulation and Design, C2EC Research Centre, School of Engineering, University of Wales Swansea, United Kingdom
J. Sienz, J.F.T. Pittman, A. Polynkin, "Simulation and Optimization for Polymer Processing", in B.H.V. Topping, C.A. Mota Soares, (Editors), "Progress in Engineering Computational Technology", Saxe-Coburg Publications, Stirlingshire, UK, Chapter 9, pp 189-218, 2004. doi:10.4203/csets.12.9
Keywords: gas assisted injection moulding, live feed mouldin, profile extrusion die design, optimisation, robust design, fluid-structure interaction.
In the first section, finite element techniques for the 3-dimensional simulation of some advanced injection moulding technologies for plastics are outlined, and applied to examples of gas assisted injection moulding and live feed injection moulding. Figure 1 shows a typical result for the simulation of the filling, the primary and the secondary gas penetration for a car door handle.
The second section introduces the simulation of uPVC profiles after leaving the profile die. This includes the heat transfer calculation and the determination of warpage. Figure 2 shows the results of the cooling simulations of a uPVC profile.
In the third section, deterministic optimisation is applied to the design of profile extrusion dies. Figure 3 shows the optimised cross-section of the profile die for the manufacture of a uPVC window profile.
In the final section, robust design techniques are applied to the design of slit dies for the manufacture of thin sheet materials. The coupled simulation solving the fluid-structure interaction problem takes the die deformation into account. Figure 4 shows the exit flow rate distribution for two cases of a choker bar profile optimisation.
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