Anda di halaman 1dari 8

Realize Your Product Promise™

Polyflow
Powerful fluid dynamics software reduces the cost
of polymer, glass, metals and cement processing.
ANSYS Polyflow accelerates design while shrinking energy and raw material demands
to make your manufacturing more cost effective and environmentally sustainable.

Polymers, glass, and even food and metals Increasing Extrusion Line Efficiency
exhibit complex nonlinear behavior while being
processed. Accurately assessing each material’s To meet tight tolerances that the market requires,
performance — well before manufacturing begins some companies resort to trial-and-error methods
— requires tailor-made software with appropriate for (co-)extruded plastic and rubber profiles.
material properties models, the capability to This approach is time intensive and costly, and
accurately capture flow domain deformations, and it can negatively impact the environment. Using
robust solvers. Companies throughout the world in engineering simulation, including our unique
the polymer, glass, metals and cement processing inverse die design capability, you can gain a
industries reduce manufacturing risk by employing significant reduction in trial-and-error iterations
ANSYS Polyflow® as an integral part of their for your extrusion lines. Some companies that
product design and optimization process. They apply our solutions have decreased the number
You can model the use this proven technology to optimize extrusion, of iterations from seven to two. Insight gleaned
manufacturing process thermoforming, blow molding, glass forming, fiber from visualizing polymer flowing throughout
and virtually test drawing and concrete shaping. the die allows you to quickly troubleshoot
packaging to evaluate unexpected problems.
and optimize performance Developing Better Packaging
as well as reduce waste.
Packaging is important to protect products from
damage — but it is also a sustainability issue
as well as an additional cost to goods suppliers.
Deploying virtual prototyping using Polyflow
enables you to model the manufacturing process.
By coupling this solution with ANSYS explicit
dynamics software and ANSYS Mechanical™,
your R&D team can evaluate and test a design’s
behavior and durability. You can take corrective
action at the design or manufacturing phase, or
both, to quickly and cost effectively design lighter
packaging with better performance.

1
Co-extrusion of soft (green) Simulation helps companies to reduce product failure risk Polyflow makes it possible to
and dense (grey) rubber for early in the design cycle by providing insight into critical study the behavior of plastics
automotive application parameters/characteristics, such as material distribution and other materials, such
(left) and top load stress distribution (middle) in a five-gallon as this example of injection
blow-molded water cooler bottle (right). stretch blow modeling using
shell elements. The image
shows thickness distribution.

Improving Performance with a Digital


Material Laboratory

Polyflow helps you to investigate behavior of new


plastics and elastomers for applications as diverse
as extrusion, blow molding, thermoforming, fiber
spinning and film casting. Simulation allows
you to test the ability to process new resins,
even before they have ever been produced, by
comparing prototypes for different materials 3-D transient modeling of fore-hearth and
to see if they match or outperform existing and single glass gob forming process
competitive materials. You can reverse-design a
resin to maximize end-product performance while
minimizing costs and environmental impact.

To understand and accurately characterize


material behavior, ANSYS provides a vast library
of mathematical material models that aid in
simulating materials.

2
Polyflow’s advanced numerics technology
allows modeling of nonlinear behavior, such
as velocity distribution in a die land and large
die swell induced by stress relaxation in a
tire application.

An advanced, application-tailored solver and extensive models deliver


the capabilities you need to optimize your manufacturing processes.

Solvers and Numerics Contact Detection

Complex rheological, thermal-dependent The manufacturing/forming process often


material behaviors, or large deformations (such involves contact between tools and materials.
as die swell, blow molding, thermoforming or Therefore, the model must accurately detect
glass pressing) are inherently nonlinear. contact between the deforming material, molds,
To meet this challenge, Polyflow uses and other tools as well as changes in mechanical
the finite element analysis method and thermal conditions before and after contact.
and a robust solver. The software Polyflow combines advanced nonlinear contact
easily accommodates deforming detection with a robust, adaptive remeshing
boundaries through its robust technique that automatically addresses these
arbitrary Lagrangian−Eulerian challenges. It also calculates mold motion.
deforming-mesh capabilities.
Mesh Superposition Technique
Visco-Elasticity and Complex
Rheology Single- and twin-screw extruders are geometri-
cally complex devices in which the flow domain
Flow characteristics of changes continually. Thermal and mechanical
materials such as plastic, interactions with the barrel or rotating screw(s)
rubber, glass, metal, food sub- are important in achieving high-quality extru-
stances and concrete depend on sions. Our software contains a validated mesh
both the material itself and its process superposition technique (MST) that allows you
Polyflow accounts for
properties, such as shear rate and thermal history. to easily build a virtual extruder, then model the
material contact in
optimizing a design, Polyflow offers many material properties models, fully filled section of the screw in a 3-D environ-
such as determining final including generalized Newtonian power, Bird– ment. Dispersive and distributive mixing models
material distribution for Carreau and Cross laws as well as visco-elastic together with particle tracking and statistical
a plug-assist thermo- models (Giesekus–Leonov, PTT and pom–pom). analysis deliver reliable tools to quantitatively
formed cup. These models accurately quantify large die swell compare different extruders and mixing devices.
encountered in some extrusion processes or exten-
sional behavior typical in forming, film-casting and
fiber-spinning applications.

3
Complex PVC extrusion die Polyflow simulates nonlinear thermal effects, which is especially important when temperature
distribution is not uniform.

Nonlinear Thermal Effects Including Radiation

Polyflow models include viscous heating to allow


you to detect potential deterioration of a poly-
mer grade or undesired rubber curing. Accurate
modeling of high-temperature processes, such
as glass forming, requires the use of advanced
nonlinear material properties, accurate radiation
prediction (using, for example, the discrete ordi-
nate radiation model) and the Narayanaswamy
model that accounts for material stress relaxation
during the cooling process.

MST in Polyflow accounts for complex thermal and mech-


anical interactions for single- and twin-screw extruders.

PVC pipes
4
Users can couple ANSYS Polyflow and ANSYS Mechanical to perform structural
analysis within the ANSYS Workbench environment.

Polyflow works with other ANSYS tools to streamline your design cycle
through Simulation-Driven Product Development.

ANSYS fluid dynamics tools are one part of our Fluid–Structure Interaction
suite that delivers advanced functionality —
depth, breadth, a plethora of advanced capabili- Polyflow includes native fluid–structure
ties and integrated multiphysics — providing interaction (FSI) to model thermomechanical
confidence that your simulation results reflect interactions between flowing materials and
real-world outcomes. The comprehensive range surrounding solids in a fully coupled approach.
of solutions provides access to virtu- When large deformations occur within the
ally any field of engineering elastic zone, the mesh resolution is automati-
simulation that a design cally refined to improve results quality.
process requires. Organi-
zations around the world You can significantly reduce time to market
trust ANSYS to help them by seamlessly exporting Polyflow results to
realize their product promises. ANSYS Mechanical software to perform structural
analysis. Using the data within ANSYS explicit
Integrated Common Environment dynamics tools, you can conduct virtual drop
tests and calculate top-loading deformation.
Polyflow assists in Polyflow software is fully integrated into the
optimal thermoforming ANSYS Workbench™ environment, so you can Optimization and Design Exploration
of an automotive dash- easily set up any problem — from standard fluid
board design. Areas flow analysis to complex interacting systems Designing equipment and processes for best
shown in blue are less simulations — with simple drag-and-drop opera- results involves evaluating multiple designs and
thick, demonstrating tions. Within Workbench, multiphysics applica- optimizing flow and geometric parameters. With
potential design
tions can access common ANSYS tools, such as ANSYS Polyflow, you can declare any scalar as
weakness.
CAD connections, geometry tools and meshing an optimization variable, including rheological
capabilities. You can use ANSYS CFD-Post™ to parameters, boundary conditions and mesh
compare results and perform final data analyses. displacements. Then you can use the built-in
These capabilities enable Simulation-Driven optimization algorithm to automatically mini-
Product Development™, which drives innovation mize or maximize a given objective function
and enables you to perform virtual prototyping, based on input parameters.
process optimization, and virtual part-testing in
a scalable and cost-effective manner.

5
ANSYS Polyflow

Geometry Mesh Multiphase Flow Inverse Die Properties Post-Processing

Flow volume Multi-zone meshing Blow molding of Die land auto- Wide range of Final thickness
automatically combines the strength water fountain matically created material of thermoformed
extracted of various meshing canister to generate correct properties and dashboad
tools to automatically extrudate after all rheological component
generate a hybrid grid deformations models
for a tidal turbine.

Pre-Processing Simulation Post-Processing Archive

Other ANSYS Engineering Simulation Capabilities

CAD Integration Multiphysics HPC Design Optimization Data Management


Courtesy I.M. Viola &
Luna Rossa.

ANSYS ANSYS Workbench To help ensure a High-performance Good design starts ANSYS EKM
DesignModeler™ and is the framework successful product, computing enables with identifying addresses critical
ANSYS SpaceClaim for the industry’s R&D teams must creation of large, the relationship issues associated
DirectModeler broadest and accurately predict high-fidelity models between perfor- with simulation
provide modeling deepest suite of how complex prod- that yield accurate mance and design data, including
and geometry advanced engineering ucts will behave in a and detailed insight. variables. ANSYS backup and
creation functions simulation tech- real-world environ- ANSYS offers scalable DesignXplorer™ archival, trace-
for fluid dynamics nology. It delivers ment. The ANSYS solutions and part- enables engineers ability and audit
analysis. The entire unprecedented suite captures the ners with hardware to perform design trail, process
ANSYS suite is productivity, enabling interaction of mul- vendors to ensure of experiments automation,
CAD independent, Simulation-Driven tiple physics: struc- that you get the (DOE) analyses, collaboration and
enabling data import Product tural, fluid dynamics, power and speed investigate response capture of engi-
from various sources. Development™. electromechanics, you need. surfaces, and neering expertise,
In addition, we and systems inter- analyze input and IP protection.
collaborate with actions. A single, constraints in
leading CAD devel- unified platform pursuit of optimal
opers to ensure an harnesses the core design candidates.
efficient workflow. physics and enables
their interoperability.

6
ANSYS, Inc. ANSYS is dedicated exclusively to developing engineering simulation software that
www.ansys.com fosters rapid and innovative product design. Our technology enables you to predict
ansysinfo@ansys.com with confidence that your product will thrive in the real world. For more than 40 years,
866.267.9724 customers in the most demanding markets have trusted our solutions to help ensure
the integrity of their products and drive business success through innovation.

ANSYS and any and all ANSYS, Inc. brand, product, service and feature names, logos and slogans are registered
trademarks or trademarks of ANSYS, Inc. or its subsidiaries in the United States or other countries. All other
brand, product, service and feature names or trademarks are the property of their respective owners.

© 2011 ANSYS, Inc. All Rights Reserved. MKT 100