Collaborative Research: Variable Geometry Dies for Polymer Extrusion

合作研究：用于聚合物挤出的可变几何模具

• 批准号: 1234374
• 负责人: Andrew Murray
• 金额: $ 31.88万
• 依托单位: University of Dayton
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2012
• 资助国家: 美国
• 起止时间: 2012-09-01 至 2017-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1234374&HistoricalAwards=false
• 关键词: Collaborative; Research; Variable; Geometry; Dies

This grant provides funding to develop variable-geometry dies for extruding complex plastic parts. Unlike most existing polymer extrusion dies, which have a single fixed geometry, design techniques will be created to build novel moving dies that morph between different shapes. Coordination of multiple actuators during the extrusion process will impose these changes in shape. The actuator locations will be optimized to provide the mechanical advantage required to resist the sizable pressure loads inside the extruder. The optimization will be accomplished with a genetic algorithm that considers the many design constraints, which include avoiding interference of moving parts, eliminating obstructions to the flow of the molten plastic, achieving a reasonably sized die, and minimizing actuator power consumption. Experimental work will develop new ways to manage the leakage of molten plastic within the die due to its moving parts. Prototype variable-geometry dies will be built and tested on a production extruder operated by an industrial collaborator. Validation experiments will derive empirical relationships between changes in the die geometry, extruder screw speed, and plastic temperature to provide process control settings that yield defect-free parts.This research seeks to create the next generation of polymer extrusion dies that can produce a wider variety of more complex plastic parts. Specifically, the work aims to enable polymer extrusion to replace injection molding for a class of plastic parts, thereby simultaneously reducing production costs and manufacturing time. Additionally, it aspires to offer designers the flexibility to create novel engineering solutions with entirely new plastic parts of varying cross sectional shape. The developed design tools will have broader application to creating other variable-geometry structures such as morphing aircraft wings and micro-scale extrusion dies.

这项拨款为开发用于挤压复杂塑料零件的可变几何模具提供资金。与大多数现有的具有单一固定几何形状的聚合物挤出模具不同，设计技术将用于构建在不同形状之间变形的新型移动模具。在挤压过程中，多个执行机构的协调将施加这些形状的变化。执行机构的位置将被优化，以提供所需的机械优势，以抵抗挤出机内的相当大的压力负载。优化将使用遗传算法来完成，该算法考虑了许多设计约束，包括避免运动部件的干扰，消除熔融塑料流动的障碍物，实现合理尺寸的模具，以及最小化执行器功耗。实验工作将开发新的方法来管理由于其运动部件而导致的模具内熔融塑料的泄漏。原型可变几何模具将建立和测试由工业合作者操作的生产挤出机。验证实验将得出模具几何形状、挤出机螺杆速度和塑料温度变化之间的经验关系，以提供生产无缺陷零件的过程控制设置。这项研究旨在创造下一代聚合物挤出模具，可以生产更多种类的更复杂的塑料部件。具体来说，这项工作旨在使聚合物挤出取代一类塑料零件的注塑成型，从而同时降低生产成本和制造时间。此外，它渴望为设计师提供灵活性，以创造全新的工程解决方案，采用不同截面形状的全新塑料部件。所开发的设计工具将更广泛地应用于其他可变几何结构的创建，如变形飞机机翼和微尺度挤压模具。