Automated generation of virtual prototypes for extrusion dies

本研究项目的动机是目前缺乏整体方法的设计和制造的挤压模具。现有的自动化仅限于优化模具的几何形状，从而形成最终产品的几何形状。挤压模具组件的其他部分，如进口、预分布和喷嘴区域，虽然它们对产品质量有影响，但大多被忽视。由于这个原因，本研究项目的目的是实现一个整体的方法来自动生成一个虚拟原型的挤压模具。除了在工艺技术方面的所有流道几何图形的全自动生成之外，制造知识也成为模型的一部分。与其他项目不同的是，在整个过程中都使用了制造就绪的3d - cad组装。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过程的一部分。在项目的第二阶段，研究再次由三个基本关键点组成。关于整体三维CFD模拟的方法，期望提高结果的质量。这将通过增加额外的影响因素来实现，例如热流变复杂材料的保留时间的影响或三维瞬态电流的实施，从而可以评估工具组件的冲洗能力。研究的另一个主要焦点是为成功测试的工具变体的智能分类提供了一种方法。这将通过为所有影响输入参数和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，提出了对相关工具变体的主模型变体的增强，以便可以包括替代预分布器变体（除了已经检查过的星型预分布）。第三个关键点将涵盖针对工具组件的不同组件的创新设计细节的新方法的开发。项目的后半部分仍将考虑在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（例如二次分配的馈电区域），通过创新方法进行了详细的优化。

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.