Automated generation of virtual prototypes for extrusion dies

本研究项目的动机是目前缺乏整体的方法来设计和制造挤出模具。现有的自动化仅限于对形成最终产品几何形状的模具的几何形状进行优化。挤出模头组件的所有其他部分，如入口、预分配和喷嘴区域，尽管它们对产品质量有影响，但大多被忽略。由于这个原因，本研究项目的目的是实施一个整体的方法自动生成的虚拟原型的挤出模具。除了在工艺技术方面完全自动生成所有流道几何形状外，制造知识也成为模型的一部分。与其他项目不同的是，整个过程都使用了3D-CAD装配。结合一致的3D-CFD分析，结果的复杂性将得到改善。此外，整个优化过程的通用性和效率是该过程的一部分。在项目的第二阶段，研究再次由三个基本的关键点组成。关于整体3D CFD模拟的方法，旨在提高结果的质量。这将通过增加额外的影响因素来实现，例如热流变复合材料的保留时间的影响或三维瞬态电流的实施，这允许对工具组件的冲洗能力进行评估。研究的另一个主要重点是提供了一种方法，成功测试的工具变体的智能分类。这将通过为所有影响输入参数和所获得的优化结果开发适当的分类属性来实现，这将允许更容易地识别这些属性之间的相关性。此外，提出了增强的主模型品种的相关工具的变体，使替代预分配器的变体可以包括（除了已经检查的星星预分配）。第三个关键点将涵盖开发新方法，用于工具组件不同组件的创新设计细节。该项目的后半部分仍将考虑制造和流变方面的流道设计方法。然而，对于流动系统的局部细节（例如二次分配的进料区域），通过创新方法进行详细的优化。

The motivation for this research project is the current lack of holistic approaches for the design and manufacturing of extrusion dies. Existing automatisms are limited to the optimization of the geometry of a die which forms out the final product geometry. All other parts of an extrusion die assembly like inlet, pre-distribution and nozzle region are mostly neglected, although they have an influence on the product quality. Because of this reason the aim of this research project is the implementation of a holistic approach for the automatic generation of a virtual prototype of an extrusion die. Besides the fully automated generation of all flow channel geometries under process technology aspects manufacturing knowledge becomes part of the model. In contrast to other projects a 3D-CAD-assembly that is manufacturing ready is used for the whole process. Combined with a consistent 3D-CFD-analysis the complexity of the results will be improved. Additionally the generality and efficiency of the whole optimization process is part of the process.In the second phase of the project, the research is once again composed of three essential key points. With regard to the approach of a holistic 3D CFD simulation an increase in quality of the results is intended. This will be achieved by adding additional factors of influence, such as the effects of the retention time of thermorheological complex materials or the implementation of three-dimensional transient currents, which allow the evaluation of the rinsing capabilities of tool assemblies. Another main focus of the research provides a methodology for the intelligent classification of successfully tested tool variants. This will be achieved by developing appropriate classification attributes for all influencing input parameters and the obtained optimization results, which will allow an easier identification of the correlation between those attributes. Furthermore, an enhancement of the master model variety for relevant tool variants is proposed, so that alternative predistributor variants can be included (in addition to the already examined star predistribution). The third key point will cover the development of new approaches for innovative design details for different components of the tool assembly. The second half of the project will still consider the design methodology of flow channels under both manufacturing and rheological aspects. For local details of the flow system however (for example the feed region of the secondary distribution), a detailed optimization is approached through innovative methods.