Automated generation of virtual prototypes for extrusion dies

这项研究项目的动机是目前缺乏全面的方法来设计和制造挤出模具。现有的自动机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。挤出模组件的所有其他部件，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。基于这个原因，本研究项目的目的是实现挤出模虚拟样机自动生成的整体方法。除了在工艺技术方面全自动生成所有流道几何图形外，制造知识也成为模型的一部分。与其他项目不同的是，整个过程都使用了可用于制造的3D-CAD-组装。结合一致的3D-CFD分析，结果的复杂性将得到改善。另外，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，研究再次由三个必要的关键点组成。关于整体三维CFD模拟的方法，目的是提高结果的质量。这将通过添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时电流的实施，这些因素允许评估工具组件的清洗能力。这项研究的另一个主要重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所获得的优化结果制定适当的分类属性来实现，这将使更容易确定这些属性之间的相关性。此外，还提出了对相关工具变量的主模型多样性的增强，以便可以包括备选的预分布变量(除了已经检查的星预分布之外)。第三个关键点将涉及为工具组件的不同部件开发创新设计细节的新方法。项目的后半部分仍将从制造和流变学两个方面考虑流道的设计方法。然而，对于流动系统的局部细节(例如二次分配的进料区)，通过创新的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.