CASE STUDY
Optimization of reducing development time for complex multi-layer profiles
With StrömungsRaum®, you virtually optimize the extrusion of complex multi-layer profiles. Precise simulations enable an accurate layer thickness distribution, reduce iteration cycles, and lower development costs—ensuring the highest quality and an accelerated production start.
Challenge
Complex multi-layer profiles, often used in the profile industry such as window profiles, impose high demands on extrusion tools. Each layer exhibits different material properties and flow behavior, requiring precise tuning within the tool. Inefficient tool development leads to long iteration cycles, high development costs, and delays in production startup.
Approach
Using StrömungsRaum®, multilayer profiles can be virtually simulated, allowing for precise analysis of the interactions between different material layers within the tool. The software simulates flow velocities, viscosities, and dwell times of each layer, enabling optimizations directly on the digital model. Risks like the occurrence of burn marks can be identified early through targeted analysis of dwell times. StrömungsRaum aids in pinpointing areas where material is over or under-extruded and assists engineers in adjusting the design to optimize material usage without compromising functionality or quality. This way, the tool design is efficiently adjusted before physical prototypes become necessary. Moreover, the simulation allows for precise distribution of layer thicknesses to ensure the desired function of the layers.
Benefits
Reduction in Development Time: The development time for complex multilayer profiles is significantly reduced, accelerating production startup.
Cost Reduction: Fewer iterations and prototypes substantially lower development costs.
Faster Market Entry: New products reach the market faster due to the more efficient development process.
Ensuring Highest Quality: The precise simulation of layer thickness distribution ensures that the finished profiles meet the highest quality standards.
Risk Minimization: Early detection of issues such as material dwell times or burn marks reduces the risk of production errors.
“Collaborating with IANUS provides us with additional insights into our own processes. We have validated the models used with our experiments. The results obtained help reduce costly experiments, enhance the performance of production facilities, and maintain the high quality of our products. The partnership package includes both the calculations and discussions with IANUS experts.” - Dr. Sven Müller
IANUS - Better Decisions.
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