Principles of Die Design

Maintain consistent flow across die width

q should remain constant at outfeed
q output flow

Fluids will want to center flow

Achieve pressure to maintain output Design for final output

Die Swell in Unfilled polymers
Die shape is different than output Doesnt happen in unfoamed WPCs

Surface quality
fluent.com/solutions/examples/img/x122i2_l.gif

Die Components
Orifice - Adapter Outlet of the extruder to the die. Typically cylindrical Entrance Section where the melt enters the die Manifold Area of the die where the melt is distributed across the section Mandrel Diverts flow to produce a hollow section of the part Land Downstream section of the die (end of die)

pslc.ws/mactest/process/restbar.htm

http://www.gatex.de/englisch/Kunststoffe-Dateien/image108%20g.jpg

Die Design
Basic Shapes
Film
Thin and flat

Rules of Thumb
Minimize amount hollow sections
Die cost Shear heating
High viscosity WPCs

Sheet
Little thicker than film

Tubular/Capillary
Hollow or solid

Avoid thick sections

Especially w/unfilled polymers

Profiled
Usually comprised of tubular and sheet concepts

Keep wall thickness consistent

Better flow

Avoid dead spots

Keep it moving

Basic Die Types

Conventional
Straight manifold

Fishtail
Manifold has varying geometry
Length of land is constant across width

Coat Hanger
Manifold has constant geometry
Diameter can vary Land length is not assumed

http://in.geocities.com/bolurpc/figlinks/exdiecastfilm.jpg

Slit Die Coat Hanger Example

Volumetric flow from the extruder QT. Volumetric flow in the capillary manifold section:

Q=

R 4 dp 8 dz

(Hagen-Poiseuille law )

** You want q to remain constant

Volumetric flow in the slit:

q=

h 3 dp h 3 p = 12 dl 12 Ll

viscosity at given shear rate p - pressure

Slit Die Example

The flow balance equation:

Q(z ) Q(z + dz ) q( z ) dz = 0
which by simplifying gives us (let z0):

dQ = q = constant dz
In constructing the function defining Q(z), let us assume that: @ z = 0, Q = QT @ z = LD, Q = 0

z Q( z ) = QT 1 L D

Linear decrease of QT along z-axis

Slit Die Example

Taking the derivative and combining with our previous definitions:

dQ QT h3 p( z ) = = dz LD 12 Ll ( z )

Rearranging we can obtain a relation for how the land length (Ll) should change along the width of the section:

Ll ( z ) =

h 3 LD p( z ) 12 QT

However, p(z) is not yet known. For this, we recall our equation defining flow in the manifold and relation we derived to define Q(z):

dp 8 z = 4 QT 1 L dz R D

Slit Die Example

Integrating we obtain:

p = po

8QT L D R 4

z 1 z L D 2 LD

Finally, we can complete our equation defining land length by substituting:

Ll =

h 3 LD p o 2h 3 L2 D 12QT 3R 4

z 1 z 2 LD 2 L D

where:

LD = half width of the section z = manifold distance from center of flow QT = volumetric output of extruder po = melt pressure R = constant manifold radius = melt viscosity at appropriate shear rate The changing length of the die land produces what is termed a coat-hanger die entrance.

Die Design WPCs

Die Flow
Wall Slip Plug Flow

Friction Material Characterization Modeling

Fluid??? Solid??

References
Michaeli, W. 2003. Extrusion Dies for Plastics and Rubber. Carl Hansen Verlag, Munich. 362pp. Oswald, T.A. 1998. Polymer Processing Fundamentals. Hanser Publishers, Inc. Cincinnati. 229 pp.