تويت
Introduction .4
Chapter one 5
Design Data 5
1.Min. & max. shear rate, shear stress and shear strain for some resin, 6
1.1. Young’s Modulus – Tensile Modulus, Modulus of Elasticity – E 6
1.2. The below table shows tensile modulus for some resin, .6
2.Shear rate .7
2.1The maximum shear rate recommended for different polymers can be obtained in
the following table: 7
3.Pressure drop 8
4.Companies (Pressure drop) 8
5.Shear stress 8
6. Design considerations of die head 10
7.Design consideration (half and full diameter) .11
8.Hard chrome plating 12
9.Die head concept for some companies, .14
9.1. Bandera .14
9.2. Bandera agri concept 14
9.3. Banderamultilayerconcept .15
9.4. Reifinghauser concept .16
9.5. Macchi conceptof thediehead .16
10.Die head concept .18
11.Hosokawa alpine .20
12. Alpine concept for barrier die head 21
13Notes of some companies: 22
13.1. Bandera .22
13.2. ETA 28
14.Dr. Collin die head concept .32
15. What is volume flow rate? .39
15.1. Is there another formula for volume flow rate? .40
15.2. Incompressibility of liquids 41
15.3. What is the equation of continuity? .42
16.Effect of die geometry on flow distribution 43
17.Dead spot .462
18.Dead spots in the die and extruder 48
18. How can we deal with the problem of polymer staying inside the extruder for too
long? .48
19.Relaxation plenum .48
20.Blown film die (Important) .50
21.Industrial Practice for the Design of Extrusion Dies .51
22.Practical Optimization Objectives 52
23.Practical Boundary Conditions and Constraints When Designing Flow Channels 53
24.Abstraction of the optimization problem .54
25.Blown film dies 56
26.Spiral Mandrel Dies 57
27.Flow coefficient .58
28.Materials 59
Chapter Two .64
Design procedures & Case studies .64
1.Input Data 65
2.1. Case study (1) done by Compuplast .66
2.2. Case study (2) done by Compuplast .72
2.3. Case study (3) done by Shouman .73
3.Hosokawa alpine die 74
4.Macroconcept .75
5. TEN LAYER DIE TECHNOLOGY .76
6.FIVE-LAYER STRUCTURES 76
7.MODULAR DIEDESIGN 77
8.BEYOND FIVE-LAYERS 78
9.MATERIALS 79
10.Avita ABA .80
11.Alpha marathon 81
11.1. Alpha marathon .81
11.2. patented Alpha Layer Sequence Repeater Die Technology. 82
12.Nano Technology Moving Fast in to Blown, Flat Film 85
12.1. FLAT FILM/SHEET ADVANCES .87
13.Patent 88
13.1. BACKGROUND OF THE INVENTION 88
13.2. SUMMARY OF THE INVENTION 89
13.3. BRIEF DESCRIPTION OF THE DRAWINGS .93
14.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS .94
15.Patent:2 .1103
15.1. BLOWING HEAD WITH MELT DISTRIBUTION .110
Chapter Three 117
Analysis Procedures 117
1.Fill 118
1.1. ANSYS DESIGN MODELER – Basic Tutorial 06 – FILL – Negative Volume .118
1.2. Setup tutorial .118
2.Ansys Mesh 119
2.1. Type and size .121
2.2. Statistics: (Skewness and aspect ratio) .121
3.Aspect Ratio 123
4.Sub task 126
5.Domain 127
5.1. To set up 127
6.Gravity .132
7.Flow boundary 135
7.1. Inflow properties 135
8.Global re-meshing .137
9. Outputs .138
10.To review the solution system type .141
11.Important remarks for the die head flow analysis using Ansys aim 142
12.ANSYS AIM: Predicting Extrudate Shape Using a Polymer Extrusion Simulation .143
13.ANSYS AIM: Determining Die Lip Shape Using a Polymer Extrusion Simulation .152
14.ANSYS AIM: Getting Started – Part 1 160
15.ANSYS AIM: Getting Started – Part 2 168
16.Multilayer procedures in Click 2 extrude .174
Chapter Four 176
Troubleshooting 176
1.Flow lines appearing in blownfilm! .177
1.2. What was the rootcause? 177
2.How it was solved? 178
3.Excessive shear .179
4.Blown Film Troubleshooting Guide (based on die head) .180
5.Some typical extrusion problems .181
5.1. Blown film quality and degradation .181
5.2. Unstable co-extrusion process 183
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