An innovative method of die design and evaluation of flow balance for thermoplastics extrusion profiles

In this article, a computational and experimental method for flow balancing of a U‐shaped die profile with nonuniform thicknesses is presented. The approach was to implement a flow restricting mechanism along the melt flow path. A parametric study based on the restrictor dimensions was carried out to attain a preliminary optimal design. Simulations were performed using Fluent software to analyze the flow velocity at the die exit. Experimental study was then carried out at various restrictor positions for the purpose of attaining a desirable flow balance. The velocity at various segments of the die exit was measured utilizing an innovative procedure by implementing the “separating blades.” Experimental findings were compared with those of simulations which showed an acceptable agreement. The results suggest that a flexible die can be designed to achieve a flow balance under various processing conditions. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers