CASE STUDY
Optimization of extrusion tools for the elastomer industry
With StrömungsRaum®, you optimize the flow distribution in extrusion tools and reduce scrap as well as tolerance deviations. Faster design iterations and precise simulations enhance product quality, reduce development times, and lower costs – for a more efficient and sustainable production.
Challenge
In the elastomer industry, plastic profiles such as seals are often manufactured through extrusion. It is crucial to design the extrusion tool with precision to produce uniform profiles. Even minor inaccuracies lead to unacceptable tolerance deviations, high wastage, and increased production costs. The flow distribution in the tool channel is particularly critical: uneven flow velocities result in asymmetric profiles and quality issues.
Approach
With StrömungsRaum®, the design of the extrusion tool is virtually simulated. The flow distribution of the melt in the tool channels is analyzed, considering variables like pressure drop, flow rate, shear rates, and viscosity. Additionally, wall slip is included in the calculations to achieve realistic simulation results. Multiple design iterations can be quickly conducted to identify and eliminate weaknesses early on—before physical prototypes are required.
Advantages
Rapid Design Iterations: Multiple tool designs can be tested and compared in a short time. Calculations for standard seal profiles are completed within a few hours.
Significant Cost Reduction: The waste rate and start-up time are reduced by up to 75%. At the same time, the need for expensive physical prototypes decreases.
Increased Precision: Simulation optimizes flow distribution, ensuring uniform profile quality and higher dimensional accuracy.
Efficient Development: Weaknesses in tool design are identified and addressed before production begins. This significantly shortens development time.
Benefits
Increase in Production Efficiency: The precise design of extrusion tools results in more consistent and defect-free profiles, enhancing overall production performance.
Reduction in Material Waste: Optimized flow distributions minimize wastage, reducing both material costs and environmental impact.
Improvement in Product Quality: Consistent profile manufacturing ensures higher dimensional accuracy and less waste, improving the quality of the final products.
Shortening of Development Times: Rapid design iterations and virtual tests accelerate tool development and shorten time-to-market.
Reduction in Overall Costs: Less waste, reduced start-up times, and the elimination of physical prototypes significantly lower production and development costs.
"We save a significant amount of laboratory work that is complex, time-consuming, and labor-intensive. It is so user-friendly that even non-engineers can operate the StrömungsRaum®." - Mikael Tekneyan
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