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Inhomogenous velocity distribution on the melt which leads to a deformation of the extrudate.
Inhomogenous velocity distribution on the melt which leads to a deformation of the extrudate.

At K 2019, SIGMA Engineering GmbH from Aachen, Germany, will give an outlook on first developments for extrusion simulation with SIGMASOFT Virtual Molding.

At the booth, SIGMA willgive an insight to its first developmental applications for the optimization of extrusion dies.

The behavior of the melt inside an extrusion die is comparable to the flow behavior inside the hot runner of thermoplastic or inside the cold runner of elastomer applications. For the extrusion die the temperature distribution inside the die alloy as well as the geometry of the flow channel also have significant influence on the flow behavior.

With countless projects for thermoplastic and elastomer applications during the last years, SIGMA can rely on broad experience in the thermal and geometrical balancing of hot and cold runner systems. Thus, it is the logical next step for SIGMA to become active in the extrusion market.

Simulation helps to identify dead spots, excessively long dwelling times in the die or high pressure losses even before the die is built. In this way, tool changing costs and excessive trial-and-error runs to find the optimum configuration are reduced. The development of a new extrusion line gets faster, cheaper and more predictable.

First test series show that especially with SIGMASOFT Autonomous Optimization flow channels of the extrusion die are automatically optimized within hours. Thus, the quality of the extrudate is distinctly improved.

To achieve this goal, geometrical degrees of freedom for the extrusion die’s flow channel are defined inside the software. SIGMASOFT then autonomously determines the ideal geometry for a dimensionally stable extrudate.

The software currently available on the market helps to calculate the temperature distribution inside the extrusion dies. However, with the help of our software and the included Virtual DoE users will be able to automatically optimize their extrusion die finding a geometry which allows for an extrusion with homogenous velocities,” explained Timo Gebauer, CTO at SIGMA.

With the optimized velocity profile inside the extrusion die the deformation of the extruded profile will be minimized.

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