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CFD Takes Guess Work Out of Manufacturing Extrusions
Posted Mon April 23, 2007 @10:15AM
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Application Getting a new extrusion die to shape a profile that meets design specifications has often been more art than science.

However, the science of CFD is now being used to shorten die-design tasks with die balancing and reverse engineering.

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The idea is to design the die that provides a particular profile from a range of operating conditions, such as throughput, melt temperature, and heating or cooling rates. It's not as easy as it sounds.

"Getting a stable extrusion not long ago involved cutting several dies guided by manufacturing experience and sometimes guesswork," says Fluent Inc. Senior Consulting Engineer Hossam Metwally. "Simpler profiles might need only two dies. But more complex shapes might need 20 or more. Besides the cost of scrapped die heads, engineering time and machine downtime to test intermediate designs added to part costs."

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