Analysis and optimization of the film cooling in industrial operating high performance blown film plants based on an integrative and calibrated process model

与任何其他挤出工艺一样，吹塑薄膜挤出受到所提供的空气冷却能力的决定性限制。通过冷却系统的优化，可以在很大程度上提高可重复生产量。该研究项目的动机可以在成果和科学知识的转移中看出，基于DFG之前的两个项目，在实验室吹塑薄膜生产线的冷却系统的计算机辅助优化到工业生产规模。除了提高产量外，重点是识别提高过程稳定性的潜力。 关于过程边界条件的显著变化，现在必须调整和转移已开发的建模方法。这一方面包括几何边界条件，另一方面包括与工艺相关的边界条件。除了主要的质量流率、冷却空气体积流以及流动现象之外，还必须考虑薄膜内部的实际变形过程以及所有主动和被动冷却部件的几何变化。这包括在工艺环境内集成内部气泡冷却装置。数值实现是通过使用成功验证和确认的过程和Prognosemodell。挑战在于在不同的工艺和冷却条件下对管材成形区进行实际计算。为此，必须记录各种实验过程条件，为以下校准过程和检查再现过程状态的能力奠定基础。在完成模型校准和验证再现能力后，主要重点将是基于模拟的系统优化潜力的实现。对于产量为1000 kg/h，口模直径高达800 mm的大容量吹塑薄膜生产线。此外，可用的材料谱必须通过新的多层化合物（3层/ 5层）来扩展，这必须考虑到建模。在与工业合作伙伴的合作中，必须在工业生产环境中对虚拟的已验证的优化潜力进行实验测试和验证，以实现提高产量的共同目标。

Like for any other extrusion process, the blown film extrusion is decisively limited by the provided air cooling capacity. Achievable throughputs can be improved by the optimization of the cooling system to a large extent. The motivation of this research project can be seen in the transfer of results and scientific knowledge, based on two preceding DFG projects, in the computer-aided optimization of cooling systems for laboratory blown film lines to industrial production scale. Besides the improvement of the output, the focus is on the identification of potentials in enhancing the process stability. With regard to remarkable changes in the process boundary conditions, one must now adapt and transfer the developed modelling approaches. This includes on the one hand geometric and on the other hand process-related boundary conditions. Besides the prevailing mass flow rates, cooling air volume flows as well as the flow phenomena, additionally the realistic deformation processes inside the film and the geometrical changes of all active and passive involved cooling components have to be taken into consideration. This included the integration of an internal bubble cooling device inside the process environment. The numerical realization is to be done by using the successfully verified and validated Prozess- and Prognosemodell. The challenge is the realistic computation of the tube formation zone at varying process- and cooling conditions. For this purpose various experimental process conditions have to be recorded, to create the basis for the following calibration process and the examination of the capability in reproducing the process state. After finishing the model calibration and proving the reproducing capabilities, the main emphasis will be on the simulation based realization of system optimization potentials.for high capacity blown film lines with output rates of 1000kg/h and die diameter up to 800mm. Furthermore the available material spectrum has to be extended by new multilayer compounds (3-layers / 5-layers), which have to be taken into account concerning the modeling. In cooperation with the industrial partner, the virtual proven optimization potentials have to be experimentally tested and validated in the industrial production environment, to meet the shared goal of improving the output.