ECCOMAS 2024

Evaluation of the Extrusion Process of a Part by Numerical Computer Simulation

  • Serrão, David (PIEP)
  • Carneiro, Filipa (PIEP)
  • Marques, Ângelo (PIEP)
  • Sousa, Pedro (PIEP)
  • Ribeiro, João (PIEP)
  • Nóbrega, Miguel (Minho University)

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The present work aims to evaluate the extrusion process of a material into a specific shape. This assessment will serve as a guide for the operation of the equipment in order to avoid rheological failures in the manufactured part. The geometry considered is two cylinders that have some intersecting volume, called “channel 8 1”. Boundary conditions consider the pressures, speeds and temperatures at the inlet and outlet of the extruder material. Initially, the material chosen will be “PP 200-CA25”, where the nonnewtonian parameters of the material will initially be defined and, based on the calculated Reynolds number, the type of flow and the appropriate viscous model will be defined. In the evaluation, firstly, the minimum length that the part must have for flow to be fully developed will be considered. After defining the minimum length of the part, a study will be carried out to determine the pressure difference that the part must have between the inlet and the outlet so that there are no defects during the extrusion of the part. Once the desired pressure difference is known, a Moody diagram will be created for the case. This Moody diagram will initially consider the physical properties of the part, in which the variables of pressure difference, Darcy friction factor and the maximum strain rate necessary so that the change in fluid fluid viscosity is not significant will be evaluated. Consequently, the same will be done for the thermal properties of the material. Regarding non-newtonian properties, two models will be compared: Power-Law model and Carreau model. The results of these two models will be compared with each other and with the experimental model. This project is part of the R2UT project. In the R2UT project, a minimalist frame will be developed using the extrusion process. Therefore, the methodology used in this project will serve as a basis for validating the R2UT project.