Page no

Contents
Introduction ...............................................................................................................4
Chapter one ................................................................................................................5
Design Data..............................................................................................................5
1.Min. & max. shear rate, shear stress and shear strain for some resin, ............................6
1.1. Young’s Modulus - Tensile Modulus, Modulus of Elasticity - E ................................6
1.2. The below table shows tensile modulus for some resin,.........................................6
2.Shear rate .................................................................................................................7
2.1The maximum shear rate recommended for different polymers can be obtained in
the following table: ..................................................................................................7
3.Pressure drop............................................................................................................8
4.Companies (Pressure drop) ........................................................................................8
5.Shear stress ..............................................................................................................8
6. Design considerations of die head ............................................................................ 10
7.Design consideration (half and full diameter)............................................................. 11
8.Hard chrome plating ................................................................................................ 12
9.Die head concept for some companies, ..................................................................... 14
9.1. Bandera ........................................................................................................... 14
9.2. Bandera agri concept .......................................................................................... 14
9.3. Banderamultilayer concept ................................................................................. 15
9.4. Reifinghauser concept ....................................................................................... 16
9.5. Macchi conceptof thediehead ............................................................................. 16
10.Die head concept ................................................................................................... 18
11.Hosokawa alpine ................................................................................................... 20
12. Alpine concept for barrier die head ........................................................................ 21
13Notes of some companies: ...................................................................................... 22
13.1. Bandera ......................................................................................................... 22
13.2. ETA ................................................................................................................ 28
14.Dr. Collin die head concept ..................................................................................... 32
15. What is volume flow rate? ..................................................................................... 39
15.1. Is there another formula for volume flow rate?................................................. 40
15.2. Incompressibility of liquids .............................................................................. 41
15.3. What is the equation of continuity? ................................................................. 42
16.Effect of die geometry on flow distribution .............................................................. 43
17.Dead spot ............................................................................................................. 46

1
18.Dead spots in the die and extruder.......................................................................... 48
18. How can we deal with the problem of polymer staying inside the extruder for too
long? ..................................................................................................................... 48
19.Relaxation plenum................................................................................................. 48
20.Blown film die (Important) ..................................................................................... 50
21.Industrial Practice for the Design of Extrusion Dies ................................................... 51
22.Practical Optimization Objectives............................................................................ 52
23.Practical Boundary Conditions and Constraints When Designing Flow Channels .......... 53
24.Abstraction of the optimization problem ................................................................. 54
25.Blown film dies ...................................................................................................... 56
26.Spiral Mandrel Dies................................................................................................ 57
27.Flow coefficient ..................................................................................................... 58
28.Materials .............................................................................................................. 59
Chapter Two............................................................................................................. 64
Design procedures & Case studies ............................................................................. 64
1.Input Data .............................................................................................................. 65
2.1. Case study (1) done by Compuplast ....................................................................... 66
2.2. Case study (2) done by Compuplast ................................................................... 72
2.3. Case study (3) done by Shouman ....................................................................... 73
3.Hosokawa alpine die ................................................................................................ 74
4.Macroconcept ......................................................................................................... 75
5. TEN LAYER DIE TECHNOLOGY ................................................................................. 76
6.FIVE-LAYER STRUCTURES ........................................................................................ 76
7.MODULAR DIEDESIGN ............................................................................................ 77
8.BEYOND FIVE-LAYERS .............................................................................................. 78
9.MATERIALS ............................................................................................................ 79
10.Avita ABA ............................................................................................................. 80
11.Alpha marathon .................................................................................................... 81
11.1. Alpha marathon ............................................................................................. 81
11.2. patented Alpha Layer Sequence Repeater Die Technology. .............................. 82
12.Nano Technology Moving Fast in to Blown, Flat Film ................................................ 85
12.1. FLAT FILM/SHEET ADVANCES ........................................................................... 87
13.Patent .................................................................................................................. 88
13.1. BACKGROUND OF THE INVENTION ................................................................ 88
13.2. SUMMARY OF THE INVENTION ...................................................................... 89
13.3. BRIEF DESCRIPTION OF THE DRAWINGS ......................................................... 93
14.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS ................................. 94
15.Patent:2 ............................................................................................................. 110

2
 15.1. BLOWING HEAD WITH MELT DISTRIBUTION ................................................. 110
Chapter Three ........................................................................................................ 117
Analysis Procedures ............................................................................................ 117
1.Fill ........................................................................................................................ 118
1.1. ANSYS DESIGN MODELER - Basic Tutorial 06 - FILL - Negative Volume ................... 118
1.2. Setup tutorial ................................................................................................. 118
2.Ansys Mesh .......................................................................................................... 119
2.1. Type and size ..................................................................................................... 121
2.2. Statistics: (Skewness and aspect ratio) ............................................................. 121
3.Aspect Ratio.......................................................................................................... 123
4.Sub task................................................................................................................ 126
5.Domain ................................................................................................................ 127
5.1. To set up ........................................................................................................ 127
6.Gravity ................................................................................................................. 132
7.Flow boundary ...................................................................................................... 135
7.1. Inflow properties ............................................................................................ 135
8.Global re-meshing ................................................................................................. 137
9. Outputs ............................................................................................................... 138
10.To review the solution system type ....................................................................... 141
11.Important remarks for the die head flow analysis using Ansys aim .......................... 142
12.ANSYS AIM: Predicting Extrudate Shape Using a Polymer Extrusion Simulation......... 143
13.ANSYS AIM: Determining Die Lip Shape Using a Polymer Extrusion Simulation ......... 152
14.ANSYS AIM: Getting Started - Part 1 ...................................................................... 160
15.ANSYS AIM: Getting Started - Part 2 ...................................................................... 168
16.Multilayer procedures in Click 2 extrude ................................................................. 174
Chapter Four .......................................................................................................... 176
Troubleshooting .................................................................................................. 176
1.Flow lines appearing in blown film! ......................................................................... 177
1.2. What was the root cause? ................................................................................ 177
2.How it was solved? ................................................................................................ 178
3.Excessive shear ..................................................................................................... 179
4.Blown Film Troubleshooting Guide (based on die head) ........................................... 180
5.Some typical extrusion problems ............................................................................. 181
5.1. Blown film quality and degradation ................................................................... 181
5.2. Unstable co-extrusion process .......................................................................... 183
Notes ...................................................................................................................... 189

3
Introduction

In this book an attempt is made to present to the

practitioner a broad picture of extrusion dies for plastics. In
pursuing that objective, the guidelines for its design given and
approaches to computational engineering analyses. This is even
more important in view of the increasing efforts made by the
industry as well as academia, starting in the recent past and
continuing in the present, to model the transport phenomena
(flow and heat transfer) in the extrusion die mathematically.
These important projects are motivated primarily by the
demand for higher productivity accompanied by better product
quality (i.e. dimensional accuracy, surface quality) of the
extruded semi-finished goods. Purely empirical engineering
methods for extrusion dies are becoming unacceptable at an
increasing rate because of economic considerations.
This book focuses on practical and explaining the necessary
material data for designing. The simple equations that are useful
for practical applications are summarized in this book. For the
majority of extrusion dies these equations are sufficient to arrive
at a realistic design based upon rheological considerations. The
various types of single and multiple layer extrusion Dies and
their specific features are highlighted in this book. The book was
written during my activity as head of the department of
Research & Development (R & D). I had access to all important
results of the research in the field of engineering of extrusion
dies.

4
Chapter one

Design Data

5
1.Min. & max. shear rate, shear stress and shear strain for some resin,

1.1. Young’s Modulus - Tensile Modulus, Modulus of Elasticity - E

E = stress / strain = σ / ε = (F / A) / (dL / L)

Young's Modulus of Elasticity (N/m2, lb/in2, psi)
Stress / Strain = Constant

The below table shows min. & max. shear rate, shear stress and shear strain for some resin,

Polymer Shear rate (S-1) Shear stress (KPa) Shear strain

Min. Max. Min. Max. Min. Max.
HDPE 5 65,000 2.5*10-5 5.45*10-5

LDPE 5 40,000 1.26*10-4 2.7*10-4

PP 5 24,000 1.98*10-5 4.28*10-5
PC 5 40,000 1.26*10-5 2.7*10-5
27.78

60

ABS 5 12,000 1.98*10-5 – 8.9*10-6 4.2*10-5 – 1.9*10-5

PA6 5 100,000 1.7*10-5 – 1.2*10-5 3.75*10-5 – 2.6*10-5
PET 5 40,000 7.9*10-6 -7.5*10-6 1.7*10-5 - 1.6*10-5
Polyester 5 1.38*10-5 – 6.9*10-6 3*10-5 - 1.5*10-5
EVOH 5 7.9*10-6 – 5.6*10-6 1.7*10-5 – 1.2*10-5

1.2. The below table shows tensile modulus for some resin,

Polymer Tensile Modulus, Modulus of Elasticity – E (GPa)

HDPE 1.1
LDPE 0.22
PP 1.4
PC 2.2
PS 2.5-3.5
PET 3.5-3.7
Polyester 2-4
PA6 1.6-2.3
ABS 1.4-3.1
EVOH 3.5-4.9

Notes:

• The minimum value leads to resin degradation

• Values which be upper than maximum leads to stresses which make shark skin
• Shear rate should be very close at multilayer merge angle otherwise produce
waves, -interfacial-instability.

6
2.Shear rate
• The range of shear rates of extrusion dies: from 10 S-1 to 104 S-1
• At the lip of the die the shear rate can be as high as 1000 s–1.
• Some die designers try to design dies for cast film or blown film operations not having
wall shear rates less than, say 10 s–1, to prevent potential hang-ups of the molten
material.
• Extrusion shear rates are normally between 50 and 1000 S-1.
• Based on Compuplast: max. shear rate is 30 S-1 & min. shear rate is 5 to 8 S-1.
• Based on Macchi: minimum shear rate 8 sec-1.
• Based on Bandera: Shear rate 5 S-1 at min. productivity
• Based on Windmoller: minimum shear rate 5 sec-1.

2.1The maximum shear rate recommended for different polymers can be obtained
in the following table:

Material Max. Shear rate (S-1)

ABS 12,000

PA 100,000

PS 40,000

PBT 40,000

PC 40,000

LDPE 40,000

HDPE 65,000

PVC 32,000

PET 40,000

PMMA 21,000

POM 40,000

PP 24,000

7
3.Pressure drop
• The total pressure drop in both dies (star-shaped distributor & ring-type distributor)
is between approximately 200 and 230 bar. In blown film dies for the processing of
polyolefins, these values can be as high as 350 bar, while the dies are designed for
pressures up to 500 bar. Nowadays, the dies are designed for pressures up to 600 bar,
while processing is usually done up to 500 bar due to more viscous materials and
cooler operating temperatures.

4.Companies (Pressure drop)

-Macchi:

Pressure drop of die head “300:305 bar

-ETA:

• Max. back pressure 300 bar or 400 bar (in spiral)

• For blown film, very thin gap: 500bar or 550 bars

-Wind Moeller:

• Ex: at the same capacity

HDPE pressure drop: 250 bar
Metallocene: 600bar
Max. pressure: 500 bar

-Bandera:
• back pressure 300 bar (in spiral)
Note: variation of pressure drop after spiral is 1 %

5.Shear stress
• With some additives, lubricants, processing aids or die coatings, the onset of
sharkskin can be shifted to a higher shear stress level, with values up to 5*10 5 Pa
being reported.
• A range of critical shear stress for polyethylene between 1*105 and 1.4*105 N/m2
(Pa), above which a wall slip generally occurs.
• For Bandera: shear stress is not allowed to exceed 60 K Pa.

8
 We simulate with our program the working condition used for the production of the
samples received and it seems that the problem is identified between layers A-B and
D-E.

The shear stress values between the mentioned layers are very high (about 130Kpa),
the recommended value in order to avoid interface instability has to be kept lower
than 80Kpa (ideally not exceeding 60Kpa!) ; from the same analysis of the 3 layer
160/180 ACH3IF blow head with matrix Ø 1800 gap 2 chromium (12CC00116) of the
previous supply, the value between the A-B and B-C layers did not exceed 74Kpa so
the problem did not emerge -attached screenshots of the simulations of the two
heads tested.

Even reducing the total output to 800 kg/h we noted that even if an improvement is
recognized, the shear value at interface remain far from the optimal value – to have a
drastic improvement of the situation it will be ideal to use LDPE on the skin layers.

Other recommended solutions:

• Change the relative percentages of the thicknesses A-B and D-E (it helps but does
not solve the problem)

• Using less viscous materials near the walls (LDPE or low viscosity LL) , lower viscosity
will reduce total stress (recommended)

• Increase temperature - at a higher temperature, reducing the viscosity of the

material

• Increase the die gap, lower the melt speed in the final gap and as a consequence
the total shear value.

Figure 1 (Over shear stress)

9
 Figure 2 (Over shear stress)

6. Design considerations of die head

1. Flow analysis based on

• Max pressure

• Min shear rate

• Converging angle

• Relaxation zone

• Die gap and shear stress ( for the shark skin and die lip dimensions)

• The shear stress should be as mentioned with COMPUPLAST in the K-show

• Review the taper angle direction not to affect the flow path ( dead spot ) (check the r
value or the spiral should be in the inner ring

2. Increase the diameter of adapter and the manifold as possible as (ETA)

(shear and pressure) and reduce the dimensions of the die cut (shear rate 5 to 8 sec-1 as
( COMPU-PLAST)
3. Centering between layers

4. Fixation

5. Thermal insulation between layers

10
 6. Assembly and thermal insulation with the air cooling ring

7. Assembly with the carriage

8. Heaters assembly

9. Air inlet

10. Thermocouples

11. Assembly with adapters

7.Design consideration (half and full diameter)

Figure (3): design consideration (half and full diameter)

The advantage of B compared to A is that b will reach to

the spiral start with a minimum depth of the channel at
the same shear rate and minimum pressure drop that
will lead as indicated to a minimum spiral helix length
which will lead to

• Lower color change time

• Minimum pressure Drop

• Minimize the die size

• Minimum degradation

11
8.Hard chrome plating
8.1. Based on Bandera: 200 µm hard chrome plating

8.2. Based on ETA: PVD coating (physical vapor deposition) (hard chrome)
Hard chrome plating

8.3. Based on Cromatora: Nickel treatment, Hard chrome plating

12
8.4. Based on Schulte

13
9.Die head concept for some companies,
9.1. Bandera

Figure (4): die head range based on Bandera

9.2. Bandera agri concept

Figure (5): Bandera agri concept

14
9.3. Bandera multilayer concept

Figure (6): Bandera multilayer concept

15
9.4. Reifinghauser concept

Figure (7): design of 5-layer die head (Reifinghauser)

9.5. Macchi concept of thediehead

Figure (8): conceptof the die head (Macchi)

16
 Figure (9): 9-layer die head scheme

Figure (10): Schematic of atypical seven-layer blown film die assemble

17
10.Die head concept

Figure (11): stack die head concept

Topic: calculation of tip & die (1/1) | wirenet.org - Official website of The Wire Association
International, Inc.

1. Unfortunately, what you are asking for in item 1 are processing parameters that have
been developed by wire and cable companies over many years and usually, they
consider them secret and a part of their intellectual property. I doubt if any wire and

18
cable company is going totell you exactly what they are doing. However, if you are
really seriousin properly developing your tooling designs, I suggest you work with a
quality manufacturer of extrusion tooling like the B&H Tool Company, Inc.
www.bhtool.com/index.html

Unfortunately, you haven't told us whether you are referring to insulating or

sheathing so we have assumed you are talking about sheathing. Likewise,we have no
idea as to whether you are referring to a commercial PVC or to an "in-house"
manufactured PVC. Finally, we have no understanding as to whether you are
referring to a semi-rigid or a fully flexible PVC. Youcertainly don't make it easy for us.

In tubing, the tip land length is often variable with the die design. Theland length of
the die is often constant or a function of the die diameter andthe polymer being
extruded. The die land length serves to hold and stabilizethe polymer pressure inside
the crosshead.

Please see the B&H Tool Company, Inc. web page www.bhtool.com/advisor-
article2.htm to view a drawing of a tubing tip and die. The classictubing design has
the tip and die land exits flush with each other at the exit ofthe crosshead as is shown
in the drawing

In pressure extrusion there often, no length of land on the tip but thedie should still
have its land length as discussed above. It is very easy to visualize the land length of
the tip in the drawing above being cut back to various semi-tubing positions before
removing the land entirely to createthe full pressure condition.

1) The die will still have its length of land as discussed in (1) above

2) Typically, the value of the Draw Down Ratio (DDR) for PVC should be around 1.5.
While the value of the Draw Ratio Balance (DRB) should beclose to 1 (+/-) (Source
- Page 260 of the Concise Encyclopedia Of Plastics.)

2. For those who wish to better understand the concept of Draw Down Ratio (DDR)
and the calculation of same, we suggest you visit this B&H Tool Company, Inc. web
page www.bhtool.com/advisor-article2.htm

19
 3. Likewise, the Draw Down Ratio Balance or Draw Ratio Balance (DRB) canbe found
atwww.bhtool.com/advisor-article3.htm
4. Clipped from: http://www.wirenet.org/wai-forums/5-electrical/2563-
calculation-of-tip-die

11.Hosokawa alpine

Figure (12): die head (Hosokawa)

20
12. Alpine concept for barrier die head

Figure (13): barrier die head (Alpine)

Alpine’s patented X-die for barrier films is designed to
accommodate each specific material in the corresponding layer to
maximize self-cleaning and reduce changeover times and raw
material consumption. The X-die is the most flexible and efficient 5-
layer die commercially available and can process a wide range of
viscosities without laminar boundary instability. Films with a
thickness of 30 µm and EVOH layers of 1 µm are easily achievable
thanks to Alpine’s new 5-layer concept.
Additional flexibility with Alpine’s patented X die for 7- and 9-
layer films
Hosokawa Alpine’s die heads for 7- and 9-layer films with the proven
X design can be adapted to suit each customer’s specific needs.
Processors must take into account many variables in their Barrier
Film criteria; for example, EVOH is triple the cost of PA, however has
gas permeability fifty to sixty times lower than PA and is three times
more rigid than PA and PE, which means that PA is not only a
superior barrier material but also offers better machine ability.
Barrier films made from 5-layer lines have only one Barrier layer
and the adjacent tie layers generally operate at relatively low
throughput rates. More complex barrier films including films with a
combination of PA and EVOH layers are produced on 7-layer lines,
and 9-layer lines offer additional versatility and flexibility in

21
 formulations and resin choices. The net result is the potential to
tailor structures to the needs of your customers and improve your
profitability.

13Notes of some companies:

13.1. Bandera

Based on Bandera:

Gusset +collapse
1800mm 14m 200mm 50 LLDPE

30% LLD 16m

• Self-cleaning
Diverging or very wide converging 100mm
Note: pressure, flow, and temperature must be uniform on the
circumference

Spiral helix

[Bandera] 5mm 20

[clockwise, counter-clockwise] [spirals]

Standard design
Residence torsion

22
 Leakage prevents
Flatness finish
Good mechanical contact (flat)
• Spiral shape

8 spirals, standard
0.75 spirals

1800 mm head 0.02 mm

Figure (14): manifold agricultural (Bandera)

23
 Geo BUR: from 101:104
Die gap (Agri - geo)
Agri: 2.5mm
Geo: 3.5mm

Spiral

18 helix
• Layer 1 (A)

Initial clearance 1mm

0.75
• Layer 2 (B)

0.75
Helix: 5mm
Die cut: 10*10

Spirals c, 3mm

24
• Layer 3 (C)

Die cut 10/11

Die insert =3.5mm for geo

• Screen changer

25
 Cupper BP plast

Die head
Finish polishing
1800mm
• Die head manufacturing

• Tolerances of insert

0.051

26
 • Barrel

Die head design: Coat hanger

Material: LDPE, LLDPE

1800 mm 10 m 70% LLD
2.5 mm die gap

• 5-layers (EVOH, PA)

Minimum capacity of the thermal sensing material for:

Interfacial instability - degradation)
10%
0.5 mm Shallow groove (PA)
Notes:

27
 Friction, hardness, Heat treatment
Annealing

IBC sensor
MICROSO NK
MIC.340/DM
K undid k 300

13.2. ETA
Up to 200 mm die insert diameter its better to make the die head as
stack (conical, stack) die

Standard for lab line 1:1.5 mm

Figure (15): die head (ETA)

1600mm 800mm [spirals] (die insert) 1600mm [head]
Analysis, 3D

Die head procedures

Non-isothermal system

Lab blown film

(Insert) 200mm stack
Head 200mm stack

Interfacial instability
Merge
Inner outer layers EVOH
Merging structure

Water control
Groove feed, oil

28
 Groove zone
0.5mm shallow groove

Notes:

• viscosity inner layer, Viscosity outer layer

• layer ratio 100

• Pressure drop increase

• Viscosity decreases
• Melt temperature increase
• Pressure variation increase

• Manufacturing of the die head

Heat treatment
Tigs fixtures

Adapter

2plates [distribution]

Stack [head]

29
• Die head insert design

Spiral distributer 5-axis

Figure (16) (Conical spiral die head W&H)

Manufacturing processes

• Rough machining
• Heat treatment
• Finishing
Stack die

• Dead spot

• Sealing
• finishing and manufacturing

Residence corners

Die insert range: 20 up to 250mm

30
 Die – head Tolerance

Die gap: Standard for lab line 1:1.5 mm

Collin
Protection of insert (die head)

Stack die head

Figure (17) (comparison of the old and new stack dies concepts, Collin)
Notes:

• Thermal separation of layer

• Short residence time
• Compact
• Easy to increase layer

For small die, (die insert) 40:100 mm

For large die, (die insert) 100:200 mm

31
 Die head

Figure (18) (comparison of the old and new stack die concepts ,Collin )

Die insert 220, BUR 2.8

Adapter

14.Dr. Collin die head concept

Figure (19): die head concept (Dr. Collin)

Notes:
The spiral is in the inner diameter because the flow will be good with the direction of the
taper angle instead of the taper angle direction in the outer insert as shown in the second
photo.

32
 Figure (20): Review of initial clearance in spirals
Increase the productivity lead to

1. Bad film
2. Channels are not bigger enough
3. Interfacial instability

Wind Moeller
BUR 1:5

Processing temp - (die)

• LD- LL -mLL [180:280 °C]
• PP [225:235 °C]
• EVOH [180:210 °C]
• PA [6 , 66][230-235 °C]
• PA6 [250-255 °C]
Notes:
• because of the higher processing temp the resin except EVOH , PA have less
bubble stability
• Water temperature control can be used to operate EVOH( 100)

33
 Target

• Processing temp as cold as Possible

• Reach high output rates
• Avoid bubble from blocking to pass without wrinkles

Nip roller temp [40:50ºC]

Cold film is flexible enough to pass the lay flat unit haul off unit without wrinkles
except some stiff HDPE

Frost line

Borders lines of film production

Extrude capacity
Back pressure
Bubble stability
High output, good quality
Mandrel size

Figure (21): small and big carriage

Small mandrel
• High flow velocity
• Low residence time
• Small risk of degradation [EVOH- tie]
• Short purging time
• High back pressure (HD, mLL

34
 Big mandrel
• Low flow velocity
• High residence time
Output (min)
• High residence time
• Low shear rate
• Low back pressure
Output (max)
• Lower residence time
• Higher shear rate
• Higher back pressure
Minimize volume inside die
Residence time
Explanation of shear rate

Sample

Starting point Possible 1 Possible 2

Output(Kg/hr) 50 50 75.7
Tube length(mm) 1000 700 700
Pressure drop(bar) 148.6 104.2 148.8

Shear rate(S-1) 19.4 19.4 37.1

Viscosity( Pa.s) 3130.8 3130.8 37.1
Tube diameter 20
Material LLDPE
Melt temperature 210ºC

35
Viscosity curve

Figure (22): shear rate and viscosity curve

✓ Higher shear rate easy flowing
✓ Lower shear rate tough flowing
So, decreasing (holes) is useful to increasing shear rate

Note:
• minimum shear rate, maximum back pressure
• The limit should be the extruder not the die
• Extruder > Limitation of the die
• Maximum pressure, maximum shear rate

Cromatora

Case 2

Figure (23) (Hard chrome plating of the die head manifold troubles, Bandera & Chromatora)

Self-cleaning
Life time

36
Die head heaters

Figure (23): die head heaters

Die head centering

On rails 1cm
Die gap (2 or 3.5)
Coat hanger distribution

Figure (24): coat hanger distribution

Exit

Figure (25): Merge angle different concepts (Bandera &Macchi)

Head

Figure (26): die head isolation

37
Double E international
Air shafts
Small web guide
Load cell
Labtech
Motor type at low productivity (Vector motor type)

Thermal insulation of die head

EVOH
• Die cut of the die

• Extruder size and motor type

• Standard screw

Figure (27): Stack type die head (Labtech)

38
 Melt flow path inside a pancake die

Figure (28): Melt flow path inside a pancake die, the die gap

15. What is volume flow rate?

From: https://www.khanacademy.org/science/physics/fluids/fluid-dynamics/a/what-is-volume-flow-rate

What does volume flow rate mean?

You might hear the term volume flow rate and think it sounds boring, but volume flow rate
keeps you alive. I'll tell you how in a second, but first we should define volume flow rate. The
volume flow rate QQQ of a fluid is defined to be the volume of fluid that is passing through a
given cross sectional area per unit time. The term cross sectional area is just a fancy term
often used to describe the area through which something is flowing, e.g., the circular area
inside the dashed line in the diagram below.

Figure (29): circular area inside the dashed line

39
 Since volume flow rate measures the amount of volume that passes through an area per time,
the equation for the volume flow rate looks like this:

In S.I. units (International System of Units), volume flow rate has units of meters cubed per
second, m3/s start fraction, m, start superscript, 3, end superscript, divided by, s, end
fraction, since it tells you the number of cubic meters of fluid that flow per second.

So how does volume flow rate keep you alive? Your heart pumps a volume of blood roughly
equal to the volume of a can of soda every four seconds.

15.1. Is there another formula for volume flow rate?

It turns out there's a useful alternative to writing the volume flow rate as

The volume of a portion of the fluid in a pipe can be written as V=Ad, equals, A, d, where Ai s
the cross-sectional area of the fluid and d is the width of that portion of fluid, see the
diagram below. We can substitute this formula for volume V into the volume flow rate to get
the following:

𝑑
But the term 𝑡
is just the length of the volume of fluid divided by the time it took the fluid to
𝑑
flow through its length, which is just the speed of the fluid. So we can replace with v in
𝑡

the previous equation and get

40
 A is the cross-sectional area of a section of the pipe, and v is the speed of the fluid in that
section. So, we get a new formula for the volume flow rate Q=Av, equals, A, v that is often
more useful than the original definition of volume flow rate because the area AAA is easy to
determine. Most pipes are cylindrical—which means the area can be found with A=πr2—and
the speed v of the fluid is a quantity that is of particular interest in many situations.

Be careful though, we're now dealing with two terms that look very similar. The volume is
represented with a capital letter V, and the speed is represented with a lowercase letter v.
People often mix up the ideas of volume, V, and speed, v, since they look so similar.

15.2. Incompressibility of liquids

It turns out that most liquids are nearly incompressible. This means that a gallon of milk can
be put into a differently shaped gallon-sized container, but you wouldn't be able to squeeze
that entire gallon of milk into a half-gallon-sized container no matter how hard you squeeze.

Because liquids are incompressible, any portion of liquid flowing through a pipe could
change shape, but it must maintain the same volume. This is true even if the pipe changes
diameter. In the diagram below, the volume, V, of liquid on the left changes shape as it
enters a narrow section of pipe, but it maintains the same volume since liquids are

incompressible.

41
15.3. What is the equation of continuity?

Liquids must maintain their volume as they flow in a pipe since they are nearly incompressible.
This means that the volume of liquid that flows into a pipe in a given amount of time must
equal the volume of liquid that flows out of a pipe in the same amount of time. For instance,
if in one hour you pump 2 m3 of water into a pipe that is already full of water, 2 m3 has
to flow out of that pipe during that same hour. The only alternatives would be for the
liquid to compress inside the pipe—which shouldn't happen—or the pipe balloons in
size—which we assume doesn't happen if the pipe is rigid. Remember, you're not
confined to considering points only at the beginning or end of the pipe, this argument
works just as well for water entering and exiting any two sections of the pipe.

So, the volume flow rate Q for an incompressible fluid at any point along a pipe is the
same as the volume flow rate at any other point along a pipe.

This can be represented mathematically with the formula Q=constant, or—choosing

any two points in the pipe—we can state mathematically that the volume flow rate is
the same at any two points by writing

𝑣
Now if we substitute the formula Q= , we get
𝑡

42
 Alternatively, we could plug in the alternative form of the volume flow rate, Q=Av, into the
formula, Q1=Q2, which would give us

This equation is known as the equation of continuity for incompressible fluids—the

previous two equations are also sometimes referred to as the equation of continuity. The
equation isn't really as mysterious as the name suggests since we found it simply by
requiring that volumes be incompressible as they flow through a pipe.

The equation is quite useful though, particularly in this form, since it says that the value of
Av, v has a constant value throughout the pipe. In other words, no matter where in the
pipe you choose to find Av, the value will always come out to be the same number for a
given pipe, if the fluid is incompressible.

So, if the area, A, of a section of pipe decreases, the speed, v, of the liquid there must increase
so that the product, Av remains the same. This means that fluids speed up when they reach
a narrow section of a pipe and slow down when they reach a wider section of a pipe. This
matches everyday experience—think about what happens if you block a portion of the water
hose with your thumb, effectively reducing its area, A. The water must come out with higher
speed, v, to ensure the volume flow rate, Av, remains the same. This is why narrow nozzles,
which reduce the area (A), attached to water hoses cause a significant increase in the speed,
v, of the fluid at that point.

16.Effect of die geometry on flow distribution

Effect of the number of grooves on flow distribution

• With five grooves the distribution is poor

• With ten grooves acceptable, and with 15 grooves very good
• An additional benefit of more grooves is reduced pressure drop
Increasing the number of grooves leads to:

1. Reduce pressure drop

2. Improve flow distribution

43
 Figure (30): effect of the number of grooves on flow distribution

Effect of taper angle on flow distribution

• The best distribution is obtained when the taper angle is 2°

• Taper angles of 1° and 3° result in a less uniform distribution

Figure (31): effect of taper angle on flow distribution

Effect of initial clearance on flow distribution

• A significant improvement in flow distribution can be obtained by using a non-zero

initial clearance. However, if the value is taken too large, the distribution becomes
more non-uniform again.
• In this example, there is an optimum value between 0 and 0.5 mm.
• A further benefit of the increased initial clearance is reduced pressure drop.

44
 Figure (32): effect of initial clearance on flow distribution

Effect of groove helix angle on flow distribution

• At a helix angle is 15°, a very good flow distribution is obtained, while the
distribution gets progressively worse when the helix angle is increased.
• A disadvantage of reduced helix angle is increased pressure drop. However,
the increase in pressure drop is rather small.

Figure (33): effect of groove helix angle on flow distribution

Effect of initial groove depth on flow distribution

• The flow distribution improves as the initial groove depth is increased.

• By increasing the groove depth from 12.5 to 25 mm the distribution uniformity
improves about 40%.

45
 Figure (34): effect of initial groove depth on flow distribution

Note: The effect of reducing groove width was studied from 19 mm initial width to 10
mm final width. Within this range of width values the reduction of groove width did
not improve the flow distribution.

17.Dead spot
• Extrusion process

Problem: Product Degradation

Cause: Residence time in the extruder, transition pipes, adapters, or die is too long,
allowing the polymer to degrade over time. Any dead spaces within the die or
transition zones allow polymer to stagnate, resulting in potential degradation as the
polymer sits at high temperature. All dies and transition pieces need to be streamlined
to prevent any dead spaces where the polymer can build up and stagnate.

Solution:

1. Reduce residence time

2. Assure no dead spaces exist in die or transition pipes

• Blown film extrusion

Problem: Lines, Streaks, or Film Contamination

Cause: Degradation in the die can be from running the die too hot, having dead
or stagnant locations in the die, and shutting down or starting up the line with
material sitting in the die at high temperatures for a long time.

46
 Solution:

1. Reduce set point temperatures

Figure (35): residence time distribution with dead spots

2. Lower die, adapter, and transfer pipe temperatures

• Cast film extrusion

Problem: Lines, Streaks, and Foreign Contamination

Cause: High temperature in the die, combined with dead or stagnant areas in the die
(behind deckles), can cause PE to cross-link and form gels.

Solution:

1. Lower melt temperature to prevent degradation, gels, and cross-linking

2. Check regrinds

3. Check feed stock

• Sheet extrusion

Problem: die lip damage causing defects in the machine direction

Cause: Polymer sticking to die or stagnating behind lip

47
18.Dead spots in the die and extruder
Dead spots in the die and extruder

Dead spots are areas inside the extruder where stagnant or slow moving polymer melt
is found. These areas may result from extruder design, or areas with polymer sticking to
the sides of the extruder which creates stagnant areas behind them. Die design is
frequently a cause of this problem.

The dead spots influence the residence time distribution. The color of the nucleus of
the oxidized gel can be used as an indication of how long the molecule spent inside the
extruder. With increasing time, the color will change from clear to brown to black.

18. How can we deal with the problem of polymer staying inside the extruder for too long?

• By reducing the temperature profile settings, we may retard radical formation and
increase the critical time required for gels to form.

• By replacing or refurbishing the screw (within certain limits) the flow back of polymer
over the screw flights is reduced and the residence time distribution narrowed.

• By optimizing the screw design for the polymer or blend being run temperature
overruns as a result of high shear areas can be minimized. For instance, by replacing
a constant pitch, increasing root screw (baseball bat design) with a decreasing pitch,
constant root design (GPDP screw) when extruding LLDPE a substantial improvement
in gel levels will be observed.

• Processing aid works by coating the metal interior of an extruder with a thin layer of
polar polymer. This layer changes the flow profile of the melt by reducing the
friction at the barrel/melt interface. The flow pattern changes to the plug flow type
and greater shear occurs at the metal polymer interface. The combination of more
polar surface and higher shear at the barrel prevents hang-up of polymer and
subsequent gel formation.

19.Relaxation plenum
As the melt leaves the spiral section at the upper portion of the mandrel where
the spiral channels feather out to tangency with the mandrel’s outside diameter, the
polymer enters into the plenum area. This area is known as the relaxation plenum; its
purpose is to relax the stresses in the polymer melt that have built up during extrusion

48
and flow to this point. Polymer that flows against the wall experiences different shear
than polymer that flows in the center of the melt channels. If the stresses are not
relaxed before the polymer flows out of the die, the resulting film product can have
weak areas and uneven gage. The length of the relaxation plenum depends on the
nature of the resin being extruded. Higher melt-index materials require a shorter
relaxation plenum, but the greater effect can be seen across material types. For
example, conventional low-density polyethylene needs a relaxation plenum of only 1
in. (25 mm). High-molecular-weight, high-density resins may need a length of 8–10 in.
(203–254 mm).
Leaving the relaxation plenum, the melt finally passes over the mandrel or die pin and
out of the die. The land length, which refers to the length or depth of the small
channel around the die between the die pin and outer die ring, is the last flow
restriction that the melt encounters before passing out of the die.

Figure (36): a typical blown-film die. (Courtesy Film aster, Inc.)

49
 Figure (37): spiral flow channel configuration. (Courtesy Film aster, Inc.)

20.Blown film die (Important)

The most common die used in blown film extrusion is the spiral mandrel die. In this
die, the polymer is divided into a number of spiraling channels with the depth of the
channels reducing in the direction of flow. The popularity of the spiral mandrel die is
due to its relatively low-pressure requirement and its excellent melt distribution
characteristics. Spiral mandrel dies can be used with a wide range of materials over a
wide range of operating conditions.

A simpler die is the conventional crosshead die; see Fig. 9.24. This design is more
susceptible to weld lines; however, with the correct design good blown film can be
produced.

The distribution characteristics of conventional crosshead dies may not be good

enough for application in blown film extrusion, where wall thicknesses are
generally quite small (the typical range is 0.005 mm to 0.25 mm). Spiral mandrel
dies can achieve good flow distribution and largely eliminate weld lines. As a
result, spiral mandrel dies are widely used in blown film extrusion.

A simplified picture of a spiral mandrel die is shown in Fig. 9.25.

50
 The incoming polymer melt stream is divided into separate feed ports. Each feed port feeds
the polymer into a spiral groove machined into the mandrel. The cross- sectional area of the
groove decreases with distance, while the gap between the mandrel and the die increases
towards the die exit. This multiplicity of flow channels results in a smearing or layering of
polymer melt from the various feed ports, yielding a good distribution of the polymer melt
exiting from the die. It is obvious that local gap adjustment is not possible as it is with flat
sheet dies. As a result, the wall thickness uniformity with spiral mandrel dies is generally not
as good as with flat sheet dies. The latter can generally achieve a wall thickness uniformity
of about ±5%, while the blown film die achieves a wall thickness uniformity of about ±10%.
For this reason, the die is generally made to rotate to evenly distribute the wall thickness
non-uniformities. If this were not done, the final roll of product would show very noticeable
variations in diameter

21.Industrial Practice for the Design of Extrusion Dies

The flow conditions in standard extrusion dies and simple profile extrusion dies with flow
channels that can be divided into sections having simple geometries can be estimated on the
basis of analytical pressure–flow relationships for simple or idealized geometries (circle, slit,
annulus). To calculate the velocity and pressure distributions, the flow channel is divided into
geometrically simple sections. For these sections, simple equations relate the flow to the
pressure loss via a flow resistance R. For a description of the resistance that is independent of
the flow, the nonlinear behavior of the melt viscosity with regard to shear rate can be
incorporated via the flow exponent n.

Figure (38): Example of simple crosshead die for blown film and spiral mandrel die

51
 Figure (39): resistance network

The following chart shows as an example the calculated velocity distribution at the outlet of a
spiral mandrel die.

Figure (40): chart shows as an example the calculated velocity distribution at the outlet of a spiral mandrel
die.

22.Practical Optimization Objectives

• Stagnation regions in which the melt can degrade as the result of excessive residence
time are to be avoided.
• Short residence times of the melt in the flow channel are the objective for materials
susceptible to thermal degradation, like PVC. In addition, it is useful in many dies to
have the narrowest possible residence-time spectrum in order to minimize the lost
time and costs associated with purging the die in the event of a material change.

52
 • A low pressure drop in the die is another criterion. Since the energy that is Introduced
by pressure forces is converted largely into heat through viscous dissipation, the melt
is heated further by this energy input. This further reduces the efficiency of the overall
process, which is often limited only by the cooling of the profile. Supplying a high
pressure also requires a more powerful and thus more expensive extruder.
• There are also other criteria, like maintaining a certain shear stress at the wall. Since
any deposits present on the wall cannot be dislodged and carried along when the
shear stress is too low, and the extrudate can be degraded when the shear stress at
the wall is too high, the shear stress at the wall should not be too low or too high. This
criterion can also be extended to the shear rates, which are closely related to the
stresses in the melt.
• When designing flow channels, it must also be ensured that the melt is subject to a
continual acceleration as it moves from the inlet to the die to the outlet. This
requirement applies especially to materials that tend to exhibit wall slip, since if the
shear stress at the wall increases monotonically along the flow path due to
acceleration of the melt a critical shear stress at which a stick-slip effect can appear
occurs only once in the die.
• with materials that exhibit highly viscoelastic behavior, the die swell should be taken
into consideration during the design process in order to promote uniform die swell
over the entire cross section, since it is possible, for instance, to compensate for this
via a higher takeoff speed.

23.Practical Boundary Conditions and Constraints When Designing Flow Channels

• The space available for the flow channel may be limited by the maximum overall
dimensions of the die, by the location of other flow channels (in coextrusion dies), or
even by other infeed channels (e. g., in coating dies).
• The selection of the flow channel geometry results only from the manufacturability of
the desired geometry.

53
 • Very high pressures are often present in the flow channels, so sufficient mechanical
strength must be provided in order to prevent a deformation of the flow channel that
could affect the optimization results.

24.Abstraction of the optimization problem

Spiral Mandrel Dies

Spiral mandrel dies for blown film extrusion [Reifenhauser]

In radial spiral distributors (Fig. A), the channels do not wind around the mandrel axially in the
conventional way, but rather lie in a plane in a radial arrangement resembling the grooves in
a phonograph record (Fig. B).

54
 Figure (41): Radial spiral distribution module [IKV, Kuhne]

Figure (42): Spiral arrangement

In this case the melt can be introduced from the outside instead of centrally from below. The
channel depth decreases toward the center so that the melt, which initially flows only in the
channel, is gradually forced over the land. The melt is finally redirected toward the die outlet
and, if desired, can be combined with additional melt layers.
A combination of an axial and a radial spiral mandrel die is represented by the conical spiral
mandrel die (Fig. C). The spirals are positioned along truncated cones instead of within a flat
plane. This variation offers advantages of both systems in a multilayer setup: as always, two
layers are within one plate, and the conical spiral mandrel die is more compact than the
classical stack die. Furthermore, adding further layers does not imply a layerwise increasing
Diameter for cylindrical spiral mandrel dies.

55
 Figure (43): Conical mandrel die

25.Blown film dies

The following figure illustrates the percentage pressure consumption in blown film dies with
a spiral mandrel with star-shaped and ring-type distributors. The high pressure consumption
in the die land and the relatively low percentage pressure drop in the spiral mandrel melt
distributor are clearly demonstrated. The total pressure drop in both dies is between
approximately 200 and 230 bar. In blown film dies for processing of polyolefins, these values
can be as high as 350 bar, while the dies are designed for pressures up to 500 bar. Nowadays,
the dies are designed for pressures up to 600 bar, while processing is usually done up to 500
bar due to more viscous materials and cooler operating temperatures.

Figure (44): Pressure loss in a blown film die [96]: 1A: inlet (star-shaped distributor);
1B: inlet (ring-type distributor); 2: rotational part; 3: spiral mandrel distributor; 4:
transition; 5: parallel die land

56
26.Spiral Mandrel Dies

For the computation a number of assumptions have to be made:

• The flows in the spiral and the annular slit are developed and do not affect each other.
• The leakage flow, leaving the spiral, has no effect on the flow in it.
• The effect of curvatures in the mandrel is neglected (same consideration as for the
problem above). This assumption is permissible because the diameter of the mandrel
is considerably greater than the diameters of the channel and the annular slit.
• The spiral is divided into segments for the purpose of the computation. From the
assumption that the isobars in the die run parallel to the exit gap, it follows (the
following figure):

Figure (45): Development geometry of a spiral distributor

The following figure shows volumetric flow rate balance at a segment of a spiral distributor

Figure (46): volumetric flow rate balance at a segment of a spiral distributor

The following figure shows: (a) leakage volume flow rate, (b) volume flow rate at the
exit (four spirals)

57
 Figure (47): (a) leakage volume flow rate, (b) volume flow rate at the exit (four spirals)

27.Flow coefficient
The flow coefficient is dependent only on the height/width ratio of the cross section under
consideration. For very small or very large H/B ratios, the flow coefficient approaches unity.
In such cases the edge effect may be neglected (the following figure)

Figure (48): Flow coefficient function for the computation of pressure loss in slits with
the consideration of the edge effect (width/height < 10)

58
 A flow coefficient function determined by the application of FEM is depicted in the following
figure. Here the pressure loss in a rectangular channel with one semicircular side was set into
a relationship with a pressure loss of a pipe with an equal hydraulic diameter.

Figure (49): Flow coefficient function for the computation of pressure loss for
rectangular flow channels with one semicircular side

28.Materials

Materials for Extrusion Dies

The materials for extrusion dies have to meet the following requirements:
• Can be readily machined (by cutting or erosion)
• Are resistant to pressure, temperature, and wear
• Have sufficient strength and toughness
• Have sufficient surface hardness
• Can be readily polished to a satisfactory surface (without porosity)
• Respond adequately to a simple heat treatment
• Have minimum tendency to distortion and change in dimensions during heat
treatment
• Are resistant to (corrosive) chemical attack
• Offer possibilities for surface treatment (e. g., chromium plating, nitriding)
• Have a good thermal conductivity
• Are stress-free

59
 The following questions must be asked when selecting the material:

• What type of compound will be processed (processing temperature range, corrosion,

increased wear, possibly by the fillers present)?
• What is the nature and the magnitude of the mechanical stresses (see Sections 9.1 to
9.3)? The bending stresses present are of significant and crucial importance for the
selection of the material. Because of their brittleness, fully hardened steels cannot be
used for larger dies [23].
• By what process is the die manufactured? Machining methods are possible for
materials with strength up to approximately 1500 N/mm2 [22]; however, the most
advantageous machining conditions exist at strengths of 600–800 N/mm2.
• What heat treatment is required and does it tend to cause distortions or dimensional
changes?

Besides the occasional few nonferrous materials, the following steels are used for the
manufacture of extrusion dies:

• Case-hardened steels
• Nitrided steels
• Fully hardened steels
• Quenched and tempered steels (to be used as supplied)
• Corrosion-resistant steels

Case-Hardened Steels

Case-hardened steels have proven their value for the manufacture of dies because they are
most likely to fulfill the necessary requirements. They are readily machined and, after case
hardening or heat treatment, have a very wear-resistant hard surface with a tough core of
high compression strength. These steels have a very low carbon content (less than 0.2 %). The
carbon content can be enriched by carburization (up to a carbon content of about 0.8% with
a carburizing depth of 0.6 to 2.0 mm), very wear-resistant carbides being formed. The regions
of the die that are not to be hardened are covered during the process. The literature should
be consulted for information about the relevant heat-treatment processes. A list of case-
hardened steels for plastics processing is given in .Primarily, the following grades are used
[24]: material nos. 1.2162 (21 MnCr 5), 1.274 (X19 NiCrMo 4), 1.2341 (X 6 CrMo 4).

60
Nitrided Steels

Nitrided steels are steels whose alloying additives—chromium, aluminum, molybdenum, and
vanadium—form hard nitrides in the presence of nitrogen (e. g., as gas (ammonia) or in a
cyanide bath) at temperatures between 480 and 580 °C and at case-hardening times of 10 to
100 hours. The nitrides lead to a high surface hardness with a tough material core. In this
process, there is no quenching after case hardening (nitriding), so no distortion is expected.
Nitrided steels are also supplied in the stress-free, annealed state. In nitriding, the greatest
hardness is achieved at about 0.03 to 0.08 mm below the surface [20]. This represents an
oversize that must be later worked off. In the so-called ion-nitriding, on the other hand, the
already finished products are hardened at the surface by a high voltage discharge in an
atmosphere containing nitrogen at about 350 to 580 °C, during which the nitrogen diffuses
into the surface. Apart from polishing the flow channel and sealing surfaces, no other finishing
work is necessary. If very wear-resistant surfaces are to be attained without increasing the
hardness of the surface greatly, the nitriding can be carried out in a salt bath (temperature
approx. 500–550 °C, case-hardening time 10 minutes to 2 hours). This is called the soft
nitriding or the Tenifer process, and it is used successfully today for the bearing surfaces of
rotating parts, such as choker bar bolts in slit dies. Nitrided steels are not completely corrosion
resistant. To improve the corrosion resistance, large amounts of chromium have to be added.
The following are some of the nitride steels: material nos. 1.2852 (33AlCrMo4), 1.2307 (29
CrMoV 9), 1.2851 (34 CrAl 16). The increase in hardness of these grades of steel is due to the
formation of martensite by precipitous cooling after heating. The resulting mechanical
properties depend to a large extent on the attainable rates of cooling.
Fully Hardened Steels

Fully hardened steels are very hard and show a good wear resistance. However, their
toughness is small when compared to that of case-hardened as well as quenched and
tempered steels. Because they are susceptible to crack formation and distortion, they are
used only infrequently and then only for small dies, primarily when there are high compressive
stresses [24]. Some fully hardened steels in polymer processing are material nos. 1.2344 (X 40
CrMoV 51),1.2367 (X 32 CrMoV 53), 1.2080 (X 210 Cr 12), 1.2379 (X 155 CrVMo 12.1), 1.2767(X
45 NiCrMo 4), and 1.2842 (90 MnCrV 8). Additional particulars can be found in.

Quenched and Tempered Steels

61
 Quenched and tempered steels, which are used as supplied, are employed whenever there is
the possibility that a heat treatment will result in distortion and dimensional changes, such as
in the case of large dies.In the manufacturing process, these steels are annealed after being
hardened. This results in a decrease in hardness and strength and an increase in toughness
and elasticity. The relatively low strength after quenching and tempering (hardening and
annealing) leads to surfaces of an inferior wear resistance and a lesser ability to be polished.
This condition, however, can be improved by nitriding or chrome plating the surfaces. Such
quenched and tempered steels are, for example, material nos. 1.2312 (40 CrMnMoS 86),
1.2347 (X CrMoVS 51), and 1.2711 (54 NiMoV 6). Additional particulars are available in.

Corrosion-Resistant Steels

These are steels containing more than 12 % chromium and are used whenever chemically
corrosive materials (e. g., hydrochloric acid) are released during plastics processing and when
it is not feasible, for technological reasons, to provide a chrome-plated or nickel-plated
surface for the flow channel. Because of the affinity of chromium for carbon (which must be
present in small amounts so that the steel can be hardened), there is a danger that chromium
carbide will be formed above 400 °C, taking chromium locally away from the area surrounding
the carbon, leading to a negative change in the properties of the and its rust resistance. As a
rule, these temperatures are not usually reached in extrusion. Corrosion-resistant steels are,
for example, material nos. 1.2083 (X 40 Cr13) and 1.2316 (X 36 CrMo17).
Based on ETA:
• die head material from ASTM (4122)

• Adapter material: Standard st.st (1.4122)

• Steal connections flanges

• Adapter coating:

Based on Cromatora:

• material of blown film die head (ASTM 17225)

62
 Based on Bandera:

• For screw & barrel: colomony

Based on Maxtrusion

• Optimum screw design with different type (Standard- Barrier- Energy transfer)
according to the material sensitivity (shear and temperature). Used for all polyolefin,
PA, EVOH without screw change.

• The screw designed to produce high output with low temperature screw supported
with dispersive and distributive Mixer.

• The feeding section could be smoothed feed with water cooled feed bush or grooved
feed bush supported with water or oil temperature control unit for cooling or heating
to improve solid conveying and increase extruder pumping action, thereby raising
output at a given extruder rpm, reducing energy put into the polymer, and lowering
melt temperature

Extruder configuration

Screw diameter L/D ratio Heating zone Driving motor Output Kg/hr.
20 26 2 5.5 4
25 30 3 7.5 8
30 30 3 11 15
40 30 4 17.5 30
45 30 4 27 60

63
Chapter Two

Design procedures & Case studies

64
1.Input Data

65
2.1. Case study (1) done by Compuplast

Procedures of FEA of spiral die

Compuplast tutorials
Geometry
Spiral die (1)
Example
Entry ports: 90°, 180°, 270°, 360° (4)
Die diameter: 4“ (101.6 mm)
Spiral flight: 3” ( 76.2 mm)
Spiral channel radius: 0.05” (1.27 mm)
Initial gap: 0.05” (1.27 mm)
Final gap: 0.15” (3.81 mm)
Spiral channel depth: 0.5” - 0” (12.7 – 0 mm)
Spiral travel one rotation: (20) adapter

Overlap for 4 spirals (imp.)

After the spiral, there is a relaxation chamber before the die exit lips.
Mass flow 150 lbs/hr. (68.03 Kg/hr.)
Die set temperature: 400 °F (204.4 °C)
Material: LDPE (1MFI)

66
Advanced Solver we use (2D, Accurate)
Expert solver at the final copy we use (3D)

The initial Data to be checked in the Spiral results

Distribution variation +/- , %
Total pressure drop Kpa or Bar

Then the details of every group of the head must be checked.

1. Adapter bar Shear S -1
Shear stress Psi
2. Ports
3. Distributer (Spiral)
✓ Pressure Drop
4. Spiral part outlet
The variation should be reviewed at the end of helix immediately
Tolerance: + - 5% is acceptable at the end of spiral, it analyzed by
Relaxation chamber or Die lip
(the average is Volumetric flow or in3/s).

67
Spirals

Should be reviewed Shear stress, Flow, Pressure drop

Shear stress not allowed to cross the line of these values psi 4.0297
(27.78KPa), because of the degradation of the materials.
Notes: these values must be checked out.
Leakage (in3/s) should be reviewed.
Note: early leakage results in poor die performance

68
 Share stress should not be lower than the recommended values
4.355(30KPa) to avoid the degradation.

Regulation steps: Design

(pressure Drop values should be taken in consideration with Spiral)
1. Decrease the value of Initial clearance.
Flow variation becomes + - 7.7% (in3/s).

69
The result: Shear stress increases
1. Increase the height of Initial clearance to regulate the leakage curve
2. Decrease the channel depth to limit the height of shear stress
The result of Flow variation is + - 10% after Spirals, it is not acceptable

70
Then the Gap value decreases and Gap height increases, then start the
calculation again.
Repeat the same process again and again till the variation is 6% its
acceptable.
The result is good but still a little space of shear stress value of spiral less
than wanted.

Section above
Then set the space next to spiral
Then add relaxation chamber
Then add Die lip
Then calculate again
Then Ran simulation
The variation value of the output not to cross 1% after Lip.

71
 Pressure drop must be checked.
(3D) Advance solver used.
At final step Expert solution used.

2.2. Case study (2) done by Compuplast

Flat film Die

Should be added. Materials, Temperature ,Flow rate

Die divided to:
1. Manifold 2. Restrictor 3. Transition 4. Relaxation chamber 5.
Lips

• Distributer

Was calculated pressure drop, variation in flow rate

Variation in flow rate: +- 1% the final
After distributer: + -5% Variation in flow rate
Volumetric flow rate: in3/S
Set All Die areas and review pressure Drop
Shear stress value must be higher than Critical shear stress.

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2.3. Case study (3) done by Shouman

Die design scheduling

1. Model the full die head layout

• Take care with the die insert

• Review from configurator the die range (this range max and
minimum will be take into account, max for the pressure and
min for the share rate)

2. Start drawing the part in the XY Plane.

a. Review the design tutorial with CATIA and ANSYS tutorial

b. Review the shear sensitive calculator in the configurator
and shear excel calculator.

3. Take care during the design of the part with (based on parameters)
Taper and runout

○Number of helix
○ During the design take care during the slot to adjust the
support surface
○ Taber angle values
○ Runout angles
4. check the initial clearance after adjust the taper value

Figure (1): initial clearance in the spiral

73
 5. Adjust the setup of Ansys
6. Adjust the die insert with the 2d Analysis as in the video

3.Hosokawa alpine die

Patent EP 2277681
From <https://www.hosokawa-alpine.com/film-extrusion/patented-technology/>
Maximum film quality through patents for blown film extrusion and film orientation.
Extensive series of trials in the Hosokawa Alpine testing center in Augsburg formed
the basis for our patented blown film process. Film die heads of different sizes were
tested with various raw materials with the same result: unparalleled film quality
even at very high throughput rates and with the shortest purging times when
changing programs. The breakthrough for the X series film die heads.

During the development of the new patented Hosokawa Alpine X film die head the
most modern computer simulation models were used. The melt feeds into the spiral
mandrel were optimized such that an extremely high flow and thermal homogeneity
of the melt is achieved. As a result of the new melt distribution in the film die heads,
the port lines on the film surface are eliminated during production of co-extrusion
films. Films of outstanding quality from the optical properties to the film thickness
profile with minimal tolerances result from this new series.
Your advantages at a glance:
• very short changeover times between different materials as a result of the
extremely short flow paths
• reduced waste as a result of short changeover times
• high output as a result of the low-pressure level in the die head
• easy accessibility due to the compact construction with a low overall height
• all surfaces in contact with polymer are coated
• Plenty of space available for the internal cooling system IBC

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4.Macroconcept

MacroPack-FP Coextrusion Dies

From <http://www.macroeng.com/flatpack-die.php>

For dies up to 500 mm in diameter, and for processors that require the layers to be
modular, Macro offers the patented Macro Pack-FP™ ‘mixing’ die design (US Patent
No 6866498). The patented design is not only able to improve the purge time by using
round channels, it can also improve the melt quality coming out of the die by using the
mixing capability of the die. The die also uses a proprietary design to prevent polymer

75
 leakage while using minimum number of bolts for ease of operations.
The modular design enables the processors to take apart only the layers that need to
be cleaned, leaving all the other layers intact; this reduces the downtime for cleaning.
This die can be used to produce structures using any barrier material including PA
(Nylon), EVOH, PETG and PVdC.

5. TEN LAYER DIE TECHNOLOGY

Brampton Engineering Inc.

ABSTRACT

Today, more than ever, the packaging sector is facing increasing demands from
consumers for improvements in packaging materials including advances in barrier
properties (including gas, aroma, etc.), mechanical requirements and chemical
resistance; puncture resistance; optical clarity; hot tack strength and sealing range;
and thermoforming properties.
In the past decade, a number of trends have emerged in blown film technology in
order to meet the aforementioned performance goals-none more influential than
the shift to multilayer co-extrusion. This paper will look at the some of the factors
driving the shift to multilayer co-extrusion from five-layer structures into seven,nine
and even 1O layers, as an alternative to lamination or extrusion coating. The ability
to achieve unusual properties or resin cost savings, as well as to meet customer
demands for new film applications, has driven blow film processors beyond the five
layer structures. The continuous improvement of the modular (stackable)
streamlined die technology has contributed to the accomplishment of multi-layer
blown film structures.

6.FIVE-LAYER STRUCTURES
The development of high barrier film using EVOH, or Nylon-EVOH required five-
layer structures. For example, a five-layer blown film structure typically being used
for meat or cheese packaging comprises 35% lonomer, 10% tie, 10% EVOH, 10%
tie, and 35% LOPE. The structure can be made with four or five extruders in a five-
layer die. The lonomer serves as the heat seal layer of the structure while the vinyl
alcohol provides the barrier layer and the LOPE gives the structure bulk and
integrity. An adhesive is fed in two thin layers to hold the incompatible skin and
core layers together.
Inthis case, the moisture-sensitive EVOH is protected by the outer polyolefin
layers when dry, EVOH can be an excellent oxygen barrier, but when exposed
to humidity, the polymer's oxygen permeability increases. The oxygen

76
 barrier layer's effectiveness would be decreased if it was not encapsulated by
a water vapor barrier layer. The lonomer layer is used to balance the structure
to add strength and primarily to provide a good heat seal. This five-layer
structure can be made more economically as a six-component film with the
same barrier properties and heat seal ability. This is accomplished by dividing
the lonomer skin layer into two components-one less expensive than the
other-while still maintaining the strength of the film as well as reducing the
cost. Comparing the cost per pound of film for the two structures, the five-
layer film has a material cost that is 15% to 20% higher than the six-layer film
which amounts to approximately $50,000 a month on a typical 40 in. wide
blown film line.

7.MODULAR DIEDESIGN
Co-extrusion was limited to five layers until 1991, when Brampton Engineering Inc.
introduced their Streamlined Co-extrusion Die (SCD) or modular (stackable) die at
the NPE >91 show in Chicago, and promptly revolutionized the process of co-
extrusion. In the SCD, all layers have approximately the same wetted surface area
becausepolymer distribution takes place on the face of the disk rather than on the
outside of a cylinder. The entire melt flow passage from the extruder adapter to the
exit of the die is highly streamlined with no sharp bends, which cause dead spots.
Consequently, the primary advantages of the modular die are its' low residence
time, streamlining and thesmall volume of molten polymer inside the die.
The design of the spiral distribution system is one of the most critical parts of die
design. Co-extrusion dies are often required to process several different resins
through the same layer, which makes de design of the distribution system more
difficult. The design of the spiral distribution system is generally done with the
assistance of computer simulation programs. The design of modular dies is a result
of basically re-orienting the distribution system. Rather than distributing the
polymer melt in the typical annular flow area, which is concentric with the axis of
the die (Figure 2), the distribution is performed in a plane which is perpendicular
to the die axis. This type of design makes each distribution system, in terms of
surface area, independent of its position. Thus this system can substantially
reduce the surface area to which the polymer is exposed in each layer. The wetted
surface areas of two five-layer dies (conventional and modular) are compared in
Figure 3. Both dies were designed to produce the same five-layer structure. The
modular design has a lower wetted surface area, which means a lower residence
time, lower pressure and lower degradation potential.

77
8.BEYOND FIVE-LAYERS

The move to multilayer co-extrusion beyond five layers has had a

dramatic impact on various market sectors such as food packaging
where barrier film can be tailor-made using different combinations of
polymers in order to provide more shelf life for a product, improve
barrier properties, and reduce costs. For example, Holmes Packaging
in Rotorua, New Zealand reports that being able to tailor-make film
has enabled the firm to prolong the shelf life of packaged cheese
products by three years.

. Prior to 1991, the major problem with the design of conventional blown film co-
extrusion dies was the material stagnation region, which caused polymer
degradation. In addition, because the outer layer in a cylindrical seven-layer die,
for example, had a polymer/metal interface six to 1O times larger than the
corresponding surface area of the inner layer, the number of layers in co-extrusion
was effectively limited to five. With new multi-layer die technology Holmes
Packaging that had first considered five-layer for their barrier films started
successfully a seven-layer line, but expanded soon to nine layers. With the type of
films, they have developed they are entering markets as far away from their home
base as Argentina and Chile.
In addition, temperature isolation between layers permits to process materials at
the best processing temperature. For example, adjacent materials could run at
temperatures up to 120 °F (59 °C) - or more; so EVOH with a processing
temperature of 440 °F (227 EC) can be sandwiched between two layers of
polyamide at 500 °F (260 °C) with reduced risk of degradation. Also consider that
another very important achievement is that a structure containing PA/EVOH/PA,
with nylon only 5 to 7% of the total film thickness, we create a "super-barrier" film.
No tie is required. And this sandwich reduces oxygen transmission 95% compared
with a five-layer film with a 20% nylon layer Figures 4 to 6 show how the structures
of multi-layer films can be modified to save money on materials and improve the
properties of the film. This leads to the 10-layer die technology, which can be
appreciated looking at Figure 7. The following are some of the improved features
of this 10-layer film:
Three layers of nylon for less stiffness - more flexibility
• Super barrier including the PA/EVOH/PA sandwich - splitting nylon layers

78
 • lonomer combined with EVA for improved sealing
• Tie layer for proper adhesion

• PA for improved seal bar release

• LLDPE for bulk
• Nylon for formability and to avoid flex crack
• Nylon for moisture barrier

• EVA to save cost (vs. ionomer)

I w from three to nine layers, with improved flexibility. Old like to

point out also that in a ten-layer die a processor could also run structures with
less layers:

As a result of the introduction of the SCD, processors have been able to move
beyond the previous limit of five-layers and have acquired six, seven, eight, and
nine-layer structures. The next step is 10layers. Introducing additional layers to
a blown film operation can provide versatility in a number of ways. For one
thing, having many layers allows the blown film line to produce a number of
different film structures. As a result, one blown film line can be used to make a
number of specialty films. Running a variety of structures on one line also
becomes more practical with product changeovers becoming faster as the
number of layers is increased. This is due to the flow passage size decreasing
individual layer modules as more modules are added while the total flow is
kept the same.

Another advantage of introducing additional layers is that it provides the

processor with increased adaptability to a changing market. Consumer demand
for packaging is constantly evolving, and having a large number of layers gives
the film producer the capability to adapt to future demands and eliminates the
need to order new capital equipment to meet changing market requirements.
Clearly, Brampton Engineering has proven the advantages of multilayer co-
extrusion.

9.MATERIALS
The performance of a multilayer barrier co-extrusion is dependent on the barrier
characteristics of the individual materials and where they are placed. A multilayer
barrier structure generally consists of a relatively expensive barrier resin co-extruded
between a less expensive structural resins. In most cases, the barrier resin restricts
the transmission of oxygen into the package to prevent the food from spoiling. The
structural resin is generally a polyolefin and is primary used to add strength to the
package and protect the barrier layer in the presence of moisture. In cases where

79
 the barrier resin does not adhere to the structural resin an additional adhesive
layer is used.
Gas transmission, which is the rate at which a substance will pass through a film, is
a critical consideration when designing barrier film structures. The rate of gas
transmission is a function of flux (rate of diffusion of a substance); diffusivity of a
substance through a solid; concentration of gas on either side of a solid; and width
of the solid.
'A multilayer die is designed with the emphasis placed on the most hard-to- process
material. Heat sensitive materials, such as EVOH and PVDC that require short
residence times demand short passages with small cross-sectional areas in order
that the velocities remain relatively high.
On the other hand, polyolefin are generally more viscous and more stable allowing
for the more open flow channels that are commonly used to keep operating
pressures low. A flow passage designed for a high viscosity polyolefin will, most
likely, have too high a residence time for a heat sensitive polymer. Conversely,
processing a high viscosity polyolefin through a flow passage designed for a heat
sensitive material will cause very high backpressures and restrict the output. A
compromise will result in a die that will process the polyolefin at below its
maximum output and will require more frequent cleaning when processing heat
sensitive materials.

10.Avita ABA

Why ABA Co-Extruder?

To save raw material cost, increase film strength and improve final
product quality.
Avita ABA Three-Layer Co-Extrusion Blown Film Machine might be the solution
for you to get in this field. The main advantage of ABA Blown Film Co-Extruder is
it significantly reduces the cost of raw material by using high percentage CaCo3 or
recycled material in Central Layer (B) and Virgin Material (or low percentage of
CaCo3) in Outer and Inner (A+A) Layer. While keep the film quality at a high level
it also applies to environmental friendly.
Even the film is not using recycled material, ABA is able to reduce the thickness
gauge by 30-50% and the film still keeps the same strength.

Avita precisely machined spiral die with high efficiency dual lip air ring can ensure
products quality with better thickness uniformity of film to increase your benefit.
One-Station Fully Automatic Winder can automatically discharge of the wound
bobbin by means of a hydraulic unloading device, with dancingroll for automatic

80
 check and tension control.
Using Co-Extrusion Blown Film Machine can improve the film strength, so you will
get a cost saving and eco-friendly product than monolayer

11.Alpha marathon

A multilayer die is designed with the emphasis placed on the most hard-
to-process material.
Heat sensitive materials, such as EVOH and PVDC that require short
residence times demand short passages with small cross-sectional areas
in order that the velocities remain relatively high.
On the other hand, polyolefins are generally more viscous and more
stable allowing for the more open flow channels that are commonly
used to keep operating pressures low. A flow passage designed for a high
viscosity polyolefin will, most likely, have too high a residence time for a
heat sensitive polymer. Conversely, processing a high viscosity polyolefin
through a flow passage designed for a heat sensitive material will cause
very high backpressures and restrict the output. A compromise will result
in a die that will process the polyolefin at below its maximum output and
will require more frequent cleaning when processing heat sensitive
materials.

11.1. Alpha marathon

Introduce Patented “LAYER SEQUENCE REPEATER”TM UP TO 200LAYERS

81
 After introducing its patented Nanolayer capable Die Technology at
NPE 2012, Alpha Marathon will be showcasing the advancements with
this technology over the past three years at Plast 2015 - May 5-9.
A full size 2X die garnered a lot of attention at NPE 2015, showcasing
the mature evolution of the innovative 1X die that was first introduced
at NPE 2012.
It is available in configurations of up to 20" diameter and from 25 to
200 layers, with an output in excess of 1000 lbs/hour.
With Blow-Up Ratios easily achievable in excess of 5 times, a 2X die is
capable of lay-flats over 13 feet.
Alpha’s "Layer Sequence Repeater" Technology represents the next
great leap forward in annular extrusion die technology for end-users
and packaging producers seeking innovative new solutions to create
higher performing and lower cost films and packaging.
It builds on the now well understood and proven principle that
increasing the layer structure of plastic films creates great
opportunities for improving their mechanical and barrier properties
while also reducing input resin and other production-costs.

The evolution from mono-layer to 3-layer co-extrusion films – and then

on to 5, 7, 9, and 11-layer co-extrusion films – is proof of this.
Alpha Marathon takes this evolution a great step forward with its:

11.2. patented Alpha Layer Sequence Repeater Die Technology.

Our "LSR" Technology is based on an innovative new approach to die

design and construction that creates film structures from 25 up to 200
discrete layers – creating never before seen film properties.
The secret is the ability to create and inter-weave layers that are less
than a micron thick. These "Nano-Layers" have unique physical and
mechanical characteristics that allow them to combine with other

82
resins in new and important ways.
Qualitative/Quantitative Phenomena
• Interweaving layers creating a repeating “I” beam
structure for maximum strength
• Adjacent ultra-thin layers rapidly quenching resulting in
“glass like” clarity, interlayer quenching
• Molecular layer alignment allowing unparalleled
extensibility for blow up ratios and orientation capability
over 1 ½ times traditional methods
• Interlayer melt stability yielding high melt strengths
allowing the creating of films under 2.5 microns in total
thickness
• Broadest tolerance of melt rheology in any extrusion
technology allowing films to be made from virtually any
resin and resin combination
Alpha's Layer Sequence Repeater Technology creates films that
exceed the performance envelopes of current multi-layer
films, including:
• Improved mechanical strength properties: increased
puncture, resistance and dart drop values
• Smoother, stronger film surfaces enhancing printing and
sealing properties
• Improved optical qualities for clear packaging
• Creation of higher performing barrier films within a
single co-extrusion
• Achievement of properties currently only possible thru
post-lamination processes within a single co-extrusion
process

Alpha Layer Sequence Repeater also creates great opportunities to

down-gauge current film applications to significantly reduce cost
without sacrificing performance. When combined with Alpha's
GlacierTM Water Quench technology, substantial production cost
reductions can be generated, including:
• 20-30% gauge reduction with no loss of mechanical properties

83
 • 5-10% reduction in input resin blend cost/kg
• 15-25% through-put increase on a linear feet or square meter
basis
• Production cost reductions thru integration of current post-
lamination processes into the co-extrusion process
Prime applications for Alpha's Nano-Layer and Glacier technologies
include:
• Food Packaging: all forms of barrier and non-barrier
applications; FFS (form/fill/seal); thermoforming (eg. Clam-
shell trays)
• Medical: IV bags and other sterile pouches
• Industrial: Heavy Duty Shipping Sacks (HDSS); shrink
bundling/hoods; vapour barrier sheeting; protective sheet
• Technology: battery and capacitor insulator films

Figure (2): Nano-Layer Structure

If you’re interested to learn how Alpha Marathon Nano-Layer Die Technology can
improve your products and cost structure, please contact us at
marketing@alphamarathon.com or nanotechnology@alphamarathon.com

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12.Nano Technology Moving Fast in to Blown, Flat Film

From: https://www.ptonline.com/articles/nano-technology-moving-fast-into-blown-flat-film

Active microlayer system from EDI relies on tooling that first forms a multilayer
sandwich of barrier, adhesive, and active-component materials from three
extruders, then multiplies that layer structure before combining it with two outer or
skin layers of material from a fourth extruder

Nanolayer extrusion technology is moving at breakneck speed. In blown film, Dow

Chemical Company, Midland, Mich., recently discussed patent-pending technology for

producing film structures with 100+ layers, while BBS Corp., Spartanburg, S.C.,
continues to advance its layer-sequence repeater technology for use with its modular
disk die.
In flat-die systems, Kuraray America, Pasadena, Tex., opened a new R&D center for
nanolayer cast film and sheet by investing more than $1 million in a pilot line furnished
by Davis-Standard LLC and Cloeren Corp. Commercial applications for nano flat film
have been thus far limited to stretch film, but as a supplier of EVOH barrier resins,

85
Kuraray’s five-extruder setup suggests developments are afoot to push the technology
into barrier cast film and sheet applications for food packaging.
Dow disclosed its technology in a paper in Boston last month at SPE’s ANTEC 2011
convention. Dr. Joseph Dooley, a Fellow at Dow’s Materials and Parts Processing
Group, delved into a new process for producing nanolayer blown film that uses feed
block and flow-splitting technology common in flat-die extrusion. In this new
configuration, the nanolayers formed by the feed block and flow splitter are fed into
an encapsulation die that is also receiving material from another extruder. Then, the
structure goes to a single manifold of a multi-manifold blown film die for final
production (see illustration). The blown film manifold containing the encapsulated
nanolayers is a crosshead-style configured with overlapping flow channels to mitigate
the formation of weld lines.
Dr. Dooley reported that initial experiments were conducted with Dow’s LDPE 501
grade in all of the layers on a 7-in. die. Alternating microlayers were pigmented to
allow examination using optical microscopy. The final 34-layer film structure consisted
of 27 alternating microlayers in the core, plus top and bottom encapsulation layers
and five layers from other die manifolds. Film thickness was 2 mil, and the 27-layer
microstructure comprised about 8% of the core layer.
In another test, Dow ran a combination of LDPE 501 alternating with its Affinity 1140
polyolefin plastomer to construct a 114-layer film consisting of 108 core layers, top
and bottom encapsulation layers, and four additional layers from four die manifolds.
Atomic force microscopy images revealed that the 108 core layers were intact near
the die entry and in the overlap region.
The Dow presentation did not cover how this technology affects film properties,
noting that the purpose of its paper was to demonstrate nanolayer processability with
its newly developed technique. Dow reports that a similar setup has been used to
produce blow molded bottles.
Interestingly, this is not the first time that flat extrusion feed block technology was
used to make nanolayer blown film. In the 1990s, Eric Hatfield at James River Corp.
(now part of Atlanta-based Printpack) developed a melt-flow multiplier for a pilot line
in Cincinnati. Hatfield also designed an 11-layer, 22-in.-diam. blown film die that he
described as a “round cast film die.” The plan, he recalls, “was to use the same
multiplier principle on it. The die was designed such that we ran 17 radically different
barrier trials in 12 hr on it.” Hatfield is currently manager of technology
implementation at specialty film processor Clopay Plastic Products, Mason, Ohio.
BBS, meantime, continues to fine-tune its layer-sequence repeater (LSR) technology,
reports company founder Hank Schirmer. The flow dividers are standardized at 25
nanolayers and can be placed anywhere within the company’s modular disk dies,
making what Schirmer describes as “unthinkable combinations in units of 25
nanolayers.” An example, he states, might be a 75-nanolayer structure using micro-
layers between each of the three 25-nanolayer bundles. BBS technology is available

86
 on full-scale blown film lines from Guangdong Jinming Machinery Co. Ltd., China.
At SPE’s Polyolefins 2011 Conference this past February, Schirmer reported trial runs
of his LSR that resulted in lower melt temperatures for EVOH when it was in nanolayer
form. “This indicated a more formable crystal structure, and this was demonstrated
by stretch-orienting the tubing containing both nylon 6 and EVOH in nanolayer form,”
Shirmer states. “So we think that other crystalline polymers behave in similar fashion
and we are pursuing 0.1-mil stretch/soft shrink film that contains PP/EVA in 25
alternating nanolayers.”
In what’s believed to be the first commercial application of nanolayer blown film,
Sealed Air, Elmwood Park, N.J., last year introduced the Cyrovac line of shrink films
made by its patented nano process. These films are said to offer better performance
than films twice as thick.

12.1. FLAT FILM/SHEET ADVANCES

In flat-die developments, Kuraray recently opened a new pilot line in Texas featuring
extrusion, downstream, and controls technology furnished by Davis-Standard,
Pawcatuck, Conn., and a die and nanolayer feedblock from Cloeren, Orange, Tex. The
line features five extruders—sized from 1 to 2 in. diam.—and Davis’ EPIC III line control
system. The system can run a wide range of thicknesses from 1 to 60 mil (an air knife
can be deployed for thin-gauge trials).
The die is a seven-layer design, but the Cloeren feedblock permits configurations up
to 21 layers. More than 50 processors attended an open house Kuraray held in April
to unveil the line. Robert Armstrong, Kuraray’s director of technical services, reports
that preliminary work showing that nanostructures improve properties such as stress-
crack resistance and orientation will pave the way for applications requiring increased
shelf life. He cited bag-in-box wine as one of these possibilities.
In another development, Extrusion Dies Industries, LLC (EDI), Chippewa Falls, Wis., has
developed a patent-pending technology that combines the concepts of active
packaging and microlayer extrusion. Called “active microlayer,” the technique
reportedly yields film and sheet in which the layer-multiplication technique is applied
not only to the barrier polymer but also to active components such as oxygen
absorbers or desiccants. This is said to add a new dimension of oxygen and moisture
control to food packaging, likely extending barrier properties beyond the limits of
standard test procedures.
EDI has already shown significant increases in shelf life of retort and hot-fill containers,
stand-up pouches, and vacuum skin packaging by dividing and recombining the barrier
layer to create many micro-barrier layers.
The combined protection of food contents by multiple—even dozens—of barrier and
active layers appears to be greater than standard tests for oxygen and moisture
ingress are designed to measure, according to Gary D. Oliver, v.p. of technology. EDI

87
 plans to produce samples for a new battery of tests at its Technology Center and then
have the results confirmed by an outside laboratory.

13.Patent
Patent No: US 8,747,725 B2

ABSTRACT

A blow head for production of a multilayer blown film with at least two plastic layers has
melt guide areas, which are traversed in succession in the direction of flow (z) of the melt,
including feed lines to at least two individual gaps for guiding an individual stream, and an
annular gap for combining of the film composite. At least one thermocouple is arranged
on at least one flow path of at least one individual stream before the stream reaches the
annular gap.

13.1. BACKGROUND OF THE INVENTION

1. Field of invention
The invention concerns a blow head for a multilayer film. Blow heads are known.
Blown films are extruded with them in blown film extruders.
2. Description of the Prior Art
For this purpose, one or more extruders convert a plastic extrudate to a plastic melt,
which is fed to the blow head. For this purpose, melting lines are used, which connect the
extruder or extruders to the blow head. Generally, the corresponding melt lines continue
in the blow head. However, here they discharge in gaps within the blow head. In blow heads
for production of multilayer film, several such gaps are provided in each blow head to
guide a single stream. The individual layers in these gaps are actually formed. For this
purpose, the individual layer or individual stream is converted from the cylindrical shape
in the feed line to a flat shape in wind-up. In 30 high-grade blow heads, the conversion can
be conducted by guiding the melt line in the peripheral direction (cp) of the blow head or
the film tube and then grading it into the flat single gap. The feed line can then grade as a coil
or sleeve into the gap. The zone, in which this transition occurs, is called the 35 melt
distribution zone in this document.
Often, but not always, a flow zone is connected to this zone, in which the melt flows along
the gap for guiding an individual stream and, in this case, is even more strongly
"accustomed" to the new flat shape. Blow heads are also known, in 40 which a feed line
grades directly into a flow zone without an extra pronounced melt distribution zone.
Finally, the gaps to guide an individual stream in blow heads for production of multilayer
films discharge into a gap for combining the film composite, which is ultimately designed
as an annular gap. The different film layers adhere to each other in this annular gap. The
annular gap ends on the round extrusion nozzle, at which the melt tube leaves the blow
head.
It is also known from DE 10 2004 001 473 Al to measure and control the thickness of the
entire film in such blow heads.

88
 For this purpose, electrically operable cartridge-type heaters are arranged in the vicinity
of the annular gap. These are in thermal contact with the melt and are capable of
supplying heat selectively to sectors of the peripheral surface of the melt tube. They are
activated when a measurement device that measures the film thickness on the periphery
of the extruded film tube finds a thick site in such a sector of the peripheral surface. Heating
of the melt of the corresponding sector increases its stretchability, so that the
corresponding sector is stretched out more strongly by the internal pressure in the bubble
than the untreated sectors. Stronger stretching out eliminates the thick site.
It is known from EP O 435 786 A2 to influence the temperature of individual melt layers
overall by massive cooling. In this way, it is supposed to be possible to connect individual
layers with strongly different processing temperature relatively damage-free into
multilayered film by cooling the hotter processed melt layer before it is supplied to the
more heat sensitive film.
Multilayer films have different film layers from sometimes 5 high-grade film material.

13.2. SUMMARY OF THE INVENTION

The task of the present invention therefore consists of proposing a blow head, with which
the thickness of individual layers within the film composite can be deliberately influ-
enced.
This task is solved in that at least one thermocouple is arranged on at least one flow path
of a single stream before reaching the annular gap.
This wording means that in the immediate spatial vicinity (in the area just a few
centimeters away from the melt stream of the single stream) of a single stream, at least
one thermo- couple is arranged, i.e., a component with which the tem perature of
these surroundings can be influenced. Naturally, the thermocouple is effectively
connected (thermally) to the single melt stream. Generally, this thermal connection is
produced at least partly by the component that limits the single melt stream. This means
it is advantageous to introduce the thermocouple into the plate or deflection piece that
limits the gap to guide a single stream on one side. However, thermocouples can also
be mounted on such a component with contact to the melt
In this case, the thermocouple is mostly in effective con-nection with the single melt
stream, on which it acts prefer- ably in the feed line to the single gaps or in the single
gaps. The at least one thermocouple will therefore lie at the level of the feed line or the
single gap in the flow direction of the melt. "In the flow direction at the level" means that
the thermo- couple is preferably effectively connected to the corresponding section of
the melt flow path (preferred effect connection=better heat transfer to this part of the
melt path of the corresponding single stream than to another part or another single
stream).
This statement is important, since there are different types of blow heads and since, in
some of these parts, the direction in which the melt flow srepeatedly changes. These
circum-stances will be taken up further below with reference to the figures. In
comparison with influencing the thickness of an entire film composite or a single-layer
film, some surprising differences emerge here:

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In the overall film thickness, the stretchability of the film as physical quantity is influenced
by introduction of temperature. Heating eliminates a thick site on the film periphery and
therefore acts against the film thickness.
In a method according to the invention, the viscosity of the melt is changed in the blow
head. Heat input increases the viscosity (preferably with reference to a selected location
on the film periphery), which means that more melt volume flows per unit time at the
same pressure. The flow rate increased in this way leads to greater thickness of the film
layer (preferably of a selected location on the film periphery). The temperature of the
melt is influenced on a single stream section with at least one thermocouple. For this
purpose, the thermocouple is effectively connected to a section or sector of a melt flow
path. Individual thick sites or thin sites can be eliminated (in sectors) on the film
periphery. Heat input of a melt flow section (by a thermocouple) increases its viscosity,
so that more melt volume emerges per unit time from the annular gap at the same
pressure and a greater film thickness is produced on a certain peripheral section. In the
reverse procedure, the opposite effects are observed.
After appropriate measurement of the thickness of a single layer, control of its thickness
(preferably with the objective of uniform thickness of the single layer) can be conducted.
The physical quantities influenced by the two methods are there- fore different and
effects of a temperature input are diametrically different.
As already mentioned, the individual gaps of high-grade blow heads often have a melt
distribution zone and a flow zone. In the melt distribution zone, the melt feed line grades
into the individual gap, in which the melt stream is converted from the frequently
cylindrical shape of the melt feed line to a flat shape, which largely corresponds to the
later film layer. In the transitional area, the feed line often assumes a coil or sleeve shape.
The coil or sleeve is opened at least in the direction of the melt stream to the gap. The
coil or sleeve generally runs in the peripheral direction of the blow head. The coils, in
particular, here have a corkscrew shape. Coils and sleeves taper in the direction of melt
transport, while the individual gap becomes wider. Finally, the coil or sleeve ends and with
it the melt distribution zone of the single gap.
Generally, a flow zone is connected to the melt distribution zone, in which the melt flows
through the gap, maintaining its new shape, and is almost "accustomed" to its shape.
Finally, the gap for guiding an individual stream discharges into a common gap, in which
all melt streams are combined.
For many applications, it has proven advantageous if at least one thermocouple is
arranged in the melt transport direction very close in front of the discharge of the melt
into the common gap. Distances from 3 to 25 centimeters, better from 5 to 18 centimeters,
are considered as advantageous ranges. Itis generally advantageous in the individual gap,
but especially in the flow area, if the at least one thermocouple is aligned "obliquely" to
the trend of the individual gap
"Obliquely" in this context means the following:
The shortest path between the transition point of the melt 35 into an individual gap and
the discharge of the individual gap into the annular gap for combining the film composite
is a straight line (geometrically rather a line segment), which runs parallel to the axis of
symmetry of the circular cylinder or truncated cone in individual gaps that have a
truncated cone or 40 circular cylindrical shape. If such an individual gap has the shape of

90
a circular disk, as in a blow head constructed according to the so-called stack-die principle,
these line segments then run from the transition point of the melt to the center of a
circular disk. Alignment of the thermocouples (or their longitudinal axes) parallel to these
line segments is advantageous. However, it is even more advantageous to provide an
angle x greater than 0° between these line segments and the thermocouples. Preferred
angles between the longitudinal axis of the thermocouples 85 and coil 15 lie between 0°
and the size of the angle between sleeves or coils and the line segment 100.
Through this expedient, the generally cylindrical thermocouples stretched along the
cylinder axis can act on the plastic melt along its actual flow direction: as long as plastic
melt of a single stream (or a single layer) is guided mostly in a melt feed line or sleeve
or coil, it is generally advantageous to arrange at least one thermocouple parallel to the
trend of this melt path segment. At the latest, at the end of the melt distribution zone,
however, the flow direction of the melt changes: within the coils or sleeves there were
determining components of melt movement in the peripheral direction of the blow
head. On leaving the sleeve or coil, however, the melt begins to move increasingly more
strongly along the line segment that marks the shortest path between the location of
the transition of the corresponding melt segment and the single gap and the discharge
of the single gap into the annular gap to guide the film composite (see above). A generally
undesired mixing of different melt layers in the gap or annular gap, in which these layers
are combined, is prevented, if the movement components in the peripheral direction of
the blow head have largely degraded up to discharge of the gap for guiding a single
stream into the gap or annular gap.
If alignment of the at least one thermocouple corresponds to the actual melt movement
at this level in the flow direction of the melt, a surface segment of the later film tube is
influenced by the effect of the thermocouple, which lies in a restricted and spatially
clearly outlined angle range of the film tube (the angle coordinates cp in the peripheral
direction of the film tube are meant in the cylindrical coordinate system of the film tube).
Thick or thin sites of the bubble can be influenced in the peripheral direction in sectors
on this account.
As already mentioned, there is an advantageous possibility of positioning the
thermocouples in the components of the blow head that guide the single stream. Before
the single streams (i.e., the melt streams that each form the single layer in the film) reach
the corresponding discharge into the common annular gap, they mostly pass through
the feed lines for the individual gaps and the individual gaps themselves. The
components that limit the individual gaps are called the distributing die for purposes of
this document. In stack-die blow heads, the components that limit the individual gaps
are often called plates, in blow heads with a central pre-distributor, they are often called
deflectors. The term distributing die is therefore the general term for "plates" and
"deflectors."
These distributing dies often limit two different, preferably adjacent gaps for guiding a
single stream. In this case, it is expedient to configure thermal connection of the
thermocouple, so that heat transfer to one single stream (if possible) is much better than
to the other. In this way, selective and exclusive influencing on a melt layer is
strengthened.
This different heat transfer can be carried out by asymmetric positioning of the

91
thermocouple in or on the distributing die. The use of material of (sharply) different
thermal conductivity also offers possibilities here of producing heat transfer of different
intensity.
In addition to additional heating, cooling of the melt during performance of the process
also works. In view of the high amounts of heat energy that are to be supplied or
withdrawn in a short time, in order to deliberately alter the viscosity of the melt, the
choice of appropriate thermocouple is not simple.
Cartridge-type heaters and Pelletier elements are considered, among others. These can
already form the thermocouple. However, it is advantageous to construct a
thermocouple from a preferably elongated (cylindrical is very good) base element. This
can be made from a material having a lower heat conductivity than the distributing die.
An active (for example, Pelletier element or cartridge-type heater, "active element") or
passive (for example, tempering agent line) heat source or sink can be arranged in this
base element.
In order to configure heat transfer to the adjacent single streams differently, an
asymmetric arrangement of heat sources and sinks in such a base element is
advantageous.
As already mentioned, it is necessary for deliberate control of local layer thicknesses
distributed over the film periphery in the cp direction to influence only partial areas
(sections) of a melt layer and thereby to leave the other layers largely uninfluenced.
It is proposed for this purpose to position the thermocouples as close as possible to
the layer being influenced, i.e., just beneath an outer surface on the distributor
element, and then to provide a heat-insulating layer on the other side that at least limits
the effect of the thermocouple on the adjacent layer.
It is then also useful to arrange the thermocouples for the innermost melt layer on the
central base part, on which no more layers are influenced.
For the film layer lying outside, it is again favorable to arrange thermocouples in the inner
surface of the outermost distributing die, since, from the outside in, no more flow paths
exist to be influenced. Careful thermal separation must there- fore be carried out only in
the middle distributor elements.
The thermocouples are preferably designed as tubular or cylindrical cartridge-type
heaters, which are common and, because of their cylindrical outer shape, have the
additional advantage that they can be simply inserted into holes. The use of relatively
longer cartridge-type heaters is therefore also possible, which permit an influence on the
viscosity over a larger flow path.
The cylindrical cartridge-type heaters are advantageously not directly inserted into
receiving holes on the distributing die, but in cylindrical support bushings, in which the
cartridge type heater is then arranged eccentrically. The distance of the thermocouple to
the outer surface can be varied by the eccentricity. At the same time, the free volume of
the support bushing has a heat-insulating effect.
The heating element can be mechanically fastened in the support bushing, so that a gas-
filled empty space remains. The empty space can also be filled with a heat-insulating
material, 25 for example, an insulating foam.
To uniformly distribute heat input on the periphery by as many thermocouples as
possible, but, on the other hand, to keep the cost for controlling the heating elements

92
 within limits, several thermocouples can be combined into groups, 30 which are then
selectively controlled. In order to set a temperature gradient, however, it can also be
advantageous to control all thermocouples simultaneously, but with different power.
It is then advantageous to provide a control device that can 35 control the individual
thermocouples independently of each other. It is also advantageous if this control device
contains information on the "thickness distribution" of the blown film present over the
peripheral direction. This information can be sent to the control device as a signal via
appropriate data lines or frequencies. The single layer thickness in individual sec- tors of
the periphery of the multilayer film tube can thus be deliberately influenced. Control of
the thickness of the single layer, with the objective of keeping it uniform over the periphery
of the film tube at a target value, is therefore possible.
Against the background of the aforementioned relations between temperature input or
cooling and thickness of a single layer, the following advantageous control methods are
conceivable:
On detection of a local thin site, the melting temperature can be increased for the
corresponding sector, so that the melt flow can be increased and the thin site eliminated.
Cooling of the remaining areas appears possible, but more difficult for technical reasons.
A local thick site can be eliminated by cooling. Here again, however, it appears more
advantageous for technical and physical reasons to drive the thermocouples of all sectors
initially with an offset temperature and to lower the temperature in the sector or sectors
in which thick sites occur. The offset should advantageously be chosen, so that in the case
of thin sites, additional potential for local temperature increase and therefore elimination
of even a thin site still exists.
As in all process steps presented in the present document, it is also advantageous in
controlling the film thickness, if the method is conducted by a control device (computer-
implemented). In this case, the control device is preferably set up by program commands,
so that they can operate the corresponding process steps by controlling the corresponding
functional components of the blow head and/or the extrusion unit.
It is advantageous to measure the thickness of the blown film single layers right after
their extrusion. If the blow film is to be flattened out and wound up, this can occur before
winding. For this purpose, one or more probes can again be used, which enclose the
peripheral surface of the blown film. It is advantageous to use at least two different
measurement principles. The total thickness of the film could be measured capacitively,
while the thickness of a specific single layer is measured by absorption of radiation (for
example, electro- magnetic radiation or beta radiation).

13.3. BRIEF DESCRIPTION OF THE DRAWINGS

The invention is further explained below with reference to the drawings. The individual
figures show:
FIG. 1a section through a stack-die blow head FIG. 2a a section through a radial
distribution insert of a blow head
FIG. 2b the same cutout as in FIG. 2a on a larger scale FIG. 3 a section through a blow
head with central pre-distributor
FIG. 4 a section through an additional blow head with central pre-distributor

93
 FIG. Sa to c cutouts of sections through additional blow heads
FIG. 6a a sketch of a single-layer blow head FIG. 6b a sketch of a single-layer blow
head
FIG. 7a a thermocouple in a schematic perspective view and
FIG. 7b a thermocouple in section
FIG. 8 a section VIII-VIII through the blown film according to FIG. 1

14.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Further scope of applicability of the present invention will become apparent from the
detailed description given herein- after. However, it should be understood that the
detailed description and specific examples, while indicating preferred embodiments of the
invention, are given by way of illustration only, since various changes and modifications
within the spirit and scope of the invention will become apparent to those skilled in the
art from this detailed description.
FIG. 1 shows a section through a stack-die blow head 1. The sectional plane is spanned
by the axial and radial coordinates z, r of the blowing head. The axial component z
simultaneously shows the feed direction of the melt in the gap to supply several single
layers. The stack-die blow head 1is supported on a foot 2, which simultaneously contains
part of the infrastructure required for the blow head (cooling air, power, sensor and
control lines). The part of the infrastructure intended for the interior of the blown film
grades into the internal tube 3, which conveys the air for internal cooling to internal
cooling 13. The internal tube 3, in turn, runs within the lower 4, middle 5 and upper 6
inner core of blow head 1. The inner cores 4, 5, 6 also delimit the nozzle gap for guiding
several single streams 17 inward and form the blow head interior in the radial direction r
of blow head 1.
The melt is fed to the depicted stack-die blow head in the radial direction r from the
outside, the lines running outside the blow head 1not being shown. Further guiding of
the melt in the blow head is assumed by the melt feed lines or radial distribution lines
14, which can only be seen in cross section in the present sectional drawing (FIG. 1). It
is not shown that the trend of these lines 14 also has radial components r, so that the
lines 14 feed the melt to the coils 15 and the second gaps for guiding a single stream
16.
The lines 14, coil 15 and second gaps 16 in the depicted practical example of a stack-die
blow head are bounded by the 5 upper and lower plate 10, 11 of a radial distribution slot
12.
The depicted blow head 1 has five such radial distribution slots 12 and therefore five such
gaps to guide several single streams 16. All these gaps discharge in the gap to guide
several single streams 17 (annular gap), in which different 10 melt streams are combined
to a composite. In the depicted practical example, the melt is moved in this gap in the z
direction and therefore the flow direction changes relative to the individual gaps 16 by
90°. At the axial end of the blow head, the melt composite passes through the nozzle 19
formed by the inner and outer extrusion lips and cools to a film 18.
The discharge points of gaps 16 for guiding the individual streams in the common gap 17
are denoted Z here. In the running direction of the melt in the individual gaps (here they

94
run in FIG. 1in the r direction toward the center of the blow 20 head), a thermocouple 85
is positioned in front of one of these discharge points Z. It shows a favorable position for
such an element. FIG. 2a shows a trend of the melt lines 14, often referred to as antlers, in
a radial distribution slot 12. FIG. 2 here is to be understood as a section through such a
radial distribution slot
12. The sectional plane is spanned by the radial r and angular coordinates cp of the blow
head. The specific type of trend and branches of the radial distribution line 14 is similar to
antlers. Initially, the melt is transferred at transfer point A from a line (not shown) running
outside the blow head, preferably between an extruder and the blow head 1, to the radial
distribution line (melt feed lines) 14 running inside the radial distribution slot 12 and
therefore inside blow head 1. This radial distribution line is branched, in order to bring
the melt as uniformly as possible to different sites on the second gap 16 for guiding an
individual stream. On reaching this gap 16 at point B, the melt line 14 grades into coil 15
in the present practical example.
FIG. 2b again shows the same cutout as FIG. 2a, in which 40 the position of a
thermocouple 85 is indicated. The line segment 100 denotes the shortest path between
point W and the common gap 17. An amount of melt leaving coil 15 through overflows
of point W and heading toward gap 17 through individual gap16, however, does not move
along the line 45 segment 100. Instead, its movement still has angular component cp,
which it gradually loses through friction. The thermocouple 85 is therefore arranged
"obliquely." The angle between the longitudinal axis of thermocouple 85 and coil 15 is
smaller than the angle between this line segment 100 and 50 coil 15. It therefore lies
between 0° and the aforementioned angle between coil 15 and line segment 100. For
graphic reasons, the depiction of a number of thermocouples 85 along the periphery of
gap 17 was dispensed with.
FIG. 3 shows a blow head 21 with a central pre-distributor 55 20. Characteristically, this
is situated at the foot of the blow head and is arranged centrally in the radial direction
r. The melt is fed via main melt lines 24 a to f to the central pre-distributor 20. For
graphic reasons, only one representative melt line 24 is shown. The pre-distributor here
consists of 60 different components 20a to 20g arranged layer-like, one above the
other. A central cavity 24 a to f is also assigned to each later melt layer, in which the
corresponding main melt line 22 a to f discharges. The melt distribution lines 25 a-g
branch off from these cavities 24 a to g. It should be noted that 65 several melt
distribution lines branch off from each cavity, only one of which is shown. This
expedient also has the objective of supplying the first gap for guiding a single stream 26a
to 26g as uniformly as possible with melt along its extent in the direction of angle
coordinate cp.
On reaching these gaps 26a to 26/, the melt distribution lines 25 a:f grade into coils
15.After the individual streams of melt in gaps 26a to 26g have been brought to their flat
shape, they reach the nozzle gap for guiding several individual streams 17 and are finally
extruded through nozzle 19.
The following must also be said concerning the mechanical structure of this blow head 21:
the central pre-distributor 20 is enclosed by the main deflector 23. The gaps for guiding
an individual stream 26a to 26/ are formed by the main deflector 23, the deflectors 27
a:f and jacket.

95
The nozzle gap 17, before discharging into the atmosphere is bounded by inner core 31,
inner ring 30 and outer ring 29. The inner core 31 has several inner parts 32 to 34.
Generally, the favorable sites for positioning of thermocouples are situated right in front
of the discharge points of the gaps for guiding the individual streams 26 a f into the
common gap 17. In the case of the first gap 26 a, which grades into common gap 17, the
discharge is assumed at point X. Point Y of discharge is shown as representative for the
other gaps for gap 26 c. The thermocouples 85 are mounted at favorable points directly
in front of the discharges. They symbolize only favorable installation locations. It is
possible to provide all gaps for guiding an individual stream with thermocouples.
The thermocouples are then advantageously distributed in larger number of the periphery
of the blow head. The mechanical structure of the blow head 41 in FIG. 4 initially acts
more clearly than the mechanical structure of blow head 21:
The additional deflectors 47 a: f are arranged above the main deflector 43. The outer ring
49 and inner ring 50 follow these deflectors. The inner tube 51 provides a position for the
feed lines for the interior of the bubble 18. The gaps for guiding an individual stream 46 a
to f are again bounded by the deflectors 43 and 47 a: f and rings 49, 50. In comparison with
blow head 21, it is conspicuous that the gaps for guiding an individual stream 47 b to f
discharge on both sides of the melt flowing through the nozzle gap for guiding several
individual streams 17. Only the first individual gap 26 a in the main flow direction z of the
melt grades directly and therefore separately into nozzle gap 17.
As discharge point into the annular gap, point U, at which the individual gaps 26 a and b
meet, is therefore assumed for individual gap 26a. As in the preceding examples, it is also
favorable here, if the thermocouple 85 c is arranged close and before this point U in the
vicinity of gap 26a. In the depicted practical example, the thermocouple has a preferred
thermal effect zone on the flow zone of gap 26a. The other thermocouples 85 a, b, d, e
are also introduced directly in front of the discharge points U and V of the corresponding
individual gaps 26 b to f
In this way, it is also possible to combine seven melt layers, but to keep the distance
between discharges of the individual gaps 26 a to f in nozzle gap 17 and the outlet of the
melt from nozzle 19 much smaller than in blow head 21. This circumstance spares the
film material.
The blow head 41 depicted in FIG. 4 also has a central pre-distributor 40, in which this
does not include different components assigned exclusively to it, like the pre-distributor
20 in blow head 21 with its parts 20 a-g. Instead, the central pre-distributor 40,
designated merely with an arrow, is prominent as component of the main deflector 43 and
deflectors 47 aj: A comparison of the two blow heads 21 and 41 or pre- distributors 20
and 40, however, reveals the basic functional common features.
The main melt lines 22 a-f or 42 a-f bring the melt to cavities 24 and 44 a-f, which are
positioned in the radial 5 direction r of the blow head best precisely in the center of the
nozzle ring. In the depicted practical examples, the main melt lines mostly run in the radial
direction r. However, it also appears possible to supply the cavities through main melt
lines running mostly in the z direction.
These cavities supply melt distribution lines 25 and 45 a-f, which generally branch off star-
like from the cavities and again discharge into the first gaps 26 for guiding an individual
stream. The reason for central positioning of cavities 22, 44 in the central pre-distributor is

96
that the different melt distribution lines 25 or 45, branching off star-like from a cavity,
which guide a melt stream and discharge in a gap 26 for guiding an individual stream,
are equally long from the cavity to the gap. In this way, the melt of an n-th melt layer
experiences the same pressure loss in all melt distribution lines 20 2Sa-f and 45a-f
assigned to it. In this way, the desired film quality can be assured.
Generally, the cavities 24 a-f or 44 a-f lie in the z direction beneath the beginning of gaps
26 a-f
FIGS. 5 a to c again illustrate preferred incorporation positions of the thermocouples 85 in
blow heads 208 a to c, whose other mechanical structure is identical and similar to the
blow head 21 depicted in FIG. 3. The path of the melt in these blow heads is bounded by
the central deflector 202, the deflectors 201 and the jacket 203. The melt flows through
a central 30 pre-distributor (not shown) into melt feed lines 205, which grade into coils
207. These release the melt by overflow into the individual gaps 200 a, b, c.At point S, the
individual gaps join to a common annular gap 17. The melt flows further and leaves the
blow head 208 a to c through a nozzle lip that is 35 already no longer shown. In blow head
208 a in FIG. Sa, the thermocouples 85 are again positioned in the vicinity of the discharge
point S. Thermocouples are only assigned to the outer individual gaps 200 a and c. This
expedient is advantageous, if an influence on the two outer layers by temperature 40
introduction on the middle layer in gap 200 b is to be avoided.
The type of positioning of thermocouples 85 minimizes mutual influencing. Moreover,
it is conspicuous that the area of effect of the thermocouples is obviously limited to the
flow area of gaps 200 a and c, since the coils 207 already end 45 earlier in the flow
direction of the film (here z). The lines 204 symbolize power and/or signal feed lines.
A cutout of an essentially similarly constructed blow head 208 b, showing the melt feed
lines 205 to the individual gaps 200 a to c, is depicted in FIG. Sb. In this practical example,
the 50 thermocouples 85 are mounted already in the immediate vicinity of the melt feed
lines 205. They therefore lie in the running direction z in the melt well in front of the
thermocouples 85 of blow head 208a. The insulation elements 206 must also be
mentioned, which ensure that the size of the 55 thermal effect of a thermocouple at least
largely remains limited to an individual gap 200 b and c. The outermost gap 200 a in the
radial direction r is selectively tempered by a thermocouple embedded in the jacket 203
of blow head 208 b.
This thermocouple does not require any special thermal sepa-60 ration from another
individual gap.
Relative to FIGS. Sa and b, FIG. Sc shows a middle part of a blow head 208c. Here the
thermocouples 85 are positioned, so that they act directly on the melt distribution zone
of gaps 200 a to c. Here the coils 207 grade into the individual gaps 65 200 a to c. The two
inner thermocouples 85 are again separated thermally by insulation elements 206 from
an individual gap 200 a, b. This expedient is unnecessary in the outer thermocouples
arranged in jacket 203.
FIGS. 6a and b show a single layer blow head 209. Significant concepts of the present
document are to be explained again with these illustrative figures. A single gap 211 is
formed in blow head 209 by the central deflector 202 and jacket 203. The central deflector
202 simultaneously serves as foot of blow head 209. The shortest path between point R,
at which an arbitrary amount of melt leaves he coil 15 by overflow, and the end of the

97
gap is the line segment 210. Between this line segment and the coil, an angle a is formed,
which is greater than angle between the longitudinal axis of the thermocouple85 and the
coil 15. Through this depicted "oblique" arrangement of the thermocouple, it is
guaranteed that the longitudinal axis of the thermocouple is aligned largely parallel to the
actually prevailing flow direction of the melt in gap 211. Naturally, this teaching can be
transferred to the conditions in gaps 16 for guiding an individual stream in blow heads 1,
21, 208 a to c according to the invention. Here the line segment runs between a point of
the coil and the discharge into the common annular gap. Here again, the angle between
coils 15 and the cartridge-type heaters lies between 0° and the angle between the same
line segment (for example, line segment 100) and coil 15.
The extent of the melt distribution and flow zone is again shown by the parentheses 212
and 213 in FIG. 6b. It is advantageous, if at least one thermocouple preferably acts on the
melt distribution and/or flow zone.
FIG. 7a shows a thermocouple 141 in a perspective view A thermal effect element 141.1,
for example, a cartridge-type heater, is integrated in support element 141.2.
As shown in the top view of FIG. 7b, the cartridge-type heater 141.1 has a much smaller
diameter in comparison to support element 141.2 and is arranged eccentrically in it, so
that adjustment of the distance to the channels guiding the melt is possible.
FIG. 8 shows a section VIII-VIII through the bubble 18 according to FIG. 1. The sectional
plane is spanned by the radial r and angular coordinates cp of the blow head. For graphic
reasons, the foot 2 and inner cooling 13 of the blow head 1are not shown. The sectors
214 are shown along the film periphery. By controlling the thickness of the individual
layer, individual thick or thin sites of an individual polymer layer of the multilayer film
that occur in such sectors can be eliminated. For this purpose, as already described at
length above, the thermocouples 85 are selectively (or individually) controlled, in order
to selectively influence the viscosity of the melt stream at certain sites. In the practical
example of FIG. 8, 8 such sectors 214 are shown. Generally, fine control of thick sites or
thin sites along the film periphery makes more than 8 sectors 214 necessary. It is naturally
also possible to assign more than one thermocouple to one such sector. In order for the
thermal effect of the thermocouple or thermocouples to act not only selectively on the
thickness of the film or film composite, but also selectively or individually on the
thickness of an individual layer, the thermocouple should be effectively connected to an
individual melt stream before it reaches the common annular gap.
The invention being thus described, it will be apparent that the same may be varied in
many ways. Such variations are not to be regarded as a departure from the spirit and
scope of the invention, and all such modifications as would be recognized by one skilled
in the art are intended to be included within the scope of the following claims.

What is claimed is:

1. A method of producing with a blow head a multilayer blown film having at least
two plastic layers, comprising the steps of:
feeding a melt to at least two individual gaps, with each of the individual gaps guiding
an individual stream of the melt, and the individual streams each forming individual
layers of the film, with at least one of the gaps that guide the individual stream having
a melt distribution zone in which a melt feed line extends into the individual gap in a

98
peripheral direction (cp) of the blow head; transferring the melt into a flat form in the
at least two individual gaps; combining of the individual streams in a common
annular gap; and influencing a temperature of at least one peripheral section of at
least one of the individual streams after leaving an extruder and before reaching the
annular gap with at least one of a plurality of thermocouples, with the
thermocouples being arranged on or in a component which borders the individual
gap and lies at least partially at a level of the individual gap in the direction of the
melt stream, a thickness of at least one of the individual layers of extruded film
and at least one sector that forms a partial area of a periphery of the blown film being
controlled with the at least one thermocouple, with at least two of the
thermocouples being assigned to different sectors that form the partial area of the
periphery of the blown film, and with the at least two thermocouples assigned to the
different sectors being controlled individually.
2. The method according to claim 1, wherein the thickness of the individual layers
of the blown film is measured before a step of winding of the blown film, and the
thickness is controlled by the temperature influence with the at least one
thermocouple.
3. The method according to claim 1, wherein the thickness of the individual layers is
determined with at least two sensors that use at least two different physical
measurement principles.
4. A blow head for production of a multilayer blown film having at least two plastic
layers, the blow head comprising at least melt-guiding areas, which are traversed
in succession in a direction of flow (z) of a melt, including feed lines to at least
two individual gaps, with each of the individual gaps guiding an individual stream of
the melt, and the individual streams each forming individual layers of the film, with
at least one of the gaps that guide the individual stream having a melt distribution
zone in which a melt feed line extends into the individual gap in a peripheral
direction (cp) of the blow head, an annular gap in which the individual gaps
discharge, and a plurality of thermocouples with which a temperature of
surroundings can be influenced, at least one of the thermocouples being
arranged on at least one flow path of at least one of the individual streams before
the individual stream reaches the annular gap, with the thermocouples being
arranged on or in a component which borders the individual gap and lies at least
partially at a level of the individual gap in the direction of the melt stream, a
thickness of at least one of the individual layers of extruded film in at least one
sector that forms a partial area of a periphery of the blown film being controlled
with the at least one thermocouple, with at least two of the thermocouples
being assigned to different sectors that form the partial area of the periphery of
the blown film, and with the at least two thermocouples assigned to the different
sectors being individually controlled.
5. The blow head according to claim 4, wherein at least one of the gaps that guide the
individual stream has a flow zone in which the melt is guided in a flattened form,
the flow zone having a shape of a ring.
6. The blow head according to claim 5, wherein at least one of the thermocouples
extends in the flow direction of the melt at least partially at the level of at least

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 one of the melt distribution zone and the flow zone.
7. The blow head according to claim 4, wherein the thermocouples are arranged
separated from the flow path of the melt by a wall area.
8. The blow head according to claim 4, wherein the thermocouples are arranged in
a distributing die.
9. The blow head according to claim 8, wherein the thermocouples are arranged
closer to a first outer surface of the distributing die than to a second outer
surface of the distributing die, and are shielded by an insulation layer relative to
the second outer surface.
10. The blow head according to claim 4, wherein at least one of the thermocouples
includes at least one Pelletier element.
11.The blow head according to claim 4, wherein at least one of the thermocouples
is formed by at least one channel that is traversable with a gas or a liquid.
12.The blow head according to claim 11, wherein the channel is associated with a
thermocouple base element that is insertable into a recess of the distributing
die.
13.The blow head according to claim 4, wherein the thermocouples are selectively
controllable individually or m groups.

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15.Patent:2
Pub. No.: US 2005/0214400 Al
ABSTRACT
A single-layer or multi-layer blowing head distributes melt essentially by horizontal spiral
mandrel distributors. As a result, the usual dead spaces underneath the otherwise
inclined spirals are avoided, which leads to better flow conditions in the blowing head
and avoids formation of specks caused by long retention times. Furthermore, the overall
height is reduced by the compact arrangement of the spirals.

15.1. BLOWING HEAD WITH MELT DISTRIBUTION

[0001] The invention relates to a single-layer or multi- layer blowing head for films and
other round bodies, in which the distribution of the melt over the circumference does not
take place in the generally customary way, by means of inclined spirals arranged
uniformly around the circumference, but instead essentially by means of horizon- tally
arranged spirals which are only offset in the region of the next feed bore by approximately
the height that corresponds to the width of the spirals and the width of the overflow gap.
In the case of the customary blowing heads, the melt distribution is carried out by means
of spirals arranged in an inclined manner. This inclined arrangement produces a region
which fills with melt underneath the spirals. The space is caused by the fact that the parts
forming the space have to be fitted or removed, and a certain amount of clearance is
necessary for this. Although it is endeavored to keep this clearance small, it is unavoidable
that it fills with melt. It has now been found that the melt penetrating into this space is
also flushed out again, the time for which it is retained there possibly amounting to
several days or even weeks. However, this leads to thermal degradation of the melt and
consequently to the formation of specks, that is to say burnt particles of plastic are
repeatedly flushed out. This leads to significant losses in quality
[0002]The purpose of the present invention is to avoid this disadvantage. To this end, it
is necessary to conduct the melt in such a way that a space in which it can be retained
for a long time cannot form in the region of the spirals. This is achieved by an arrangement
of spirals which avoids the dead space. To this end, the spirals are arranged essentially
horizontally and placed so close to the sealing surface that the entire region is optimally
flowed through and consequently also flushed. The invention is explained in more detail
with reference to the accompanying drawings.
[0003]The invention is explained in more detail on the basis of exemplary embodiments
represented in the accompanying drawings, in which:
[0004] FIG. 1 schematically shows a blowing head with an arrangement of inclined spirals;
[0005] FIG. 2 shows a section through such a blowing head;
[0006] FIG. 3 shows the developed projection of these spirals;
[0007] FIG. 4 shows the developed projection of the arrangement of spirals according to the

110
invention;
[0008] FIG. 4.1 shows various spiral configurations according to the invention;
[0009] FIG. 5 shows a section through a blowing head in the region of the beginning of
the spiral;
[0010] FIG. 6 shows another section through a blowing head in the region of the
beginning of the spiral; and
[0011] FIG. 7 shows a detailed representation of FIG. 6.
[0012] FIG. 1 schematically shows the construction of a blowing head with inclined spiral
mandrel distributors 1. The melt comes from the center, flows into the spirals and is
distributed by continuously flowing out of the spirals 1via the overflow gap to the blowing
head outlet.
[0013] FIG. 2 shows a section through such a blowing head. The melt flows out of the
central feed bore 3 into the spirals 1. Underneath the spirals, a small gap 2 is represented.
This gap 2 is intended to be as small as possible, to minimize the entry of melt into this
space 2. This gap 2 is necessary to allow the outer ring 2.1 to be fitted.
[0014] FIG. 3 shows the developed projection of the spirals 4 and the space 2.2 lying
thereunder, into which the melt flows. This space 2.2 is flushed very poorly, since the
melt normally flows only in the direction of the outlet. However, it has been found that,
in this space 2.2, the melt will, after it has flowed in, also slowly be flushed out again.
This process may take several days; in the meantime, the melt degrades and is flushed
out again as burnt specks. This may mean that specks are continually produced and
flushed out.
[0015]The solution according to the invention provides for this region to be kept as small
as possible or avoided entirely.
[0016] FIG. 4 shows a developed projection of the solution according to the invention.
The spirals 8 are horizon- tally mounted. They are supplied with melt via feed bore 10.
The horizontal arrangement has the effect that the space 5 underneath the spirals 8 is
brought to a very small volume. The spirals remain in the lowermost region up to the
next feed bore 10 and are then taken over by the next spiral, the previous spiral
extending away at an angle upward and then running parallel to the lower spiral, the
new plane being displaced upward by the width of the spiral 21 and the overflow gap
22. In the case represented, four-fold super- posing is therefore obtained. In spite of the
four-fold super- posing, the overall height of all the spirals, with the height 7, is small in
comparison with the conventional arrangement. The cross section 6 of the individual
spirals 8 decreases over the length of the spirals, the degree of cross-sectional reduction
being potentially dependent on various factors.
[0017] FIG. 4.1 shows other configurations of the spirals. Spiral 8.1 would lead to five-fold
superposing, spiral 8.2 to three-fold superposing.
[0018] FIG. 5 shows a detail of a blowing in the region of the arrangement of spirals. The
inner mandrel 16 is cylindrical and is inserted into the pot-shaped outer casing
17. For production engineering reasons, the beginning of the spiral 6 is therefore set
very low, so that the dead space 5 is very small. In the case represented, the overflow

111
 gap 9 begins at approximately half the height 12 of the lower plane of the spirals.
[0019] In FIG. 6, the inner mandrel comprises a cylindrical part and a supporting ring
19.1. This form does not normally allow the spirals to be produced at the lowest point of
the melt channel. To be able nevertheless to set the spirals at the lowest point, a small
step 11 is provided, and this is at the same time the sealing surface. Since it has a
diameter that is only a little larger than the cylindrical surface of the spiral ring, it is no
problem for the spirals to be produced at this point. The outer casing 18 is actually
accepted on the pressure-bearing surface 20 and the sealing surface 11, the pressure-
bearing surface 20 having a clearance of one hundredth of a millimeter in the
untightened state.
[0020] FIG. 7 shows the details from FIG. 6 once again in an enlarged form. The sealing
surface 11is located directly at the lower plane of the spirals 6. This produces a very
small dead space 13, which is only 1-2 mm high. The annular surface 15 does not serve
as a sealing surface but as a supporting surface. With the outer casing 18, it forms a
small air gap of a few hundredths of a millimeter, while the annular surface 20 is formed
as a supporting surface. In this way it is ensured that the full contact pressure acts on
the pressure-bearing surface 15. In the case represented, the overflow gap 9 begins at
point 12. The point 12 may, however, also be higher or lower.
1-6. (canceled)
7. A blowing head for extruding single-layer or multi- layer films or tubes, with a
spiral mandrel distributor system for distributing melt over a circumference including a
cylin-drical spiral mandrel and an outer casing defining a melt channel there between,
said spiral mandrel having a vertical longitudinal axis and defining open spiral channels
on an outer circumference open to the melt channel, each of the spiral channels being
respectively connected to a feed bore for receiving melt, said spirals extending
substantially hori-zontally on said spiral mandrel and extending at an angle upward
proximate successive circumferential regions of the feed bores by a vertical distance of
a width of the spiral channel and an overflow gap The blowing head of claim 7, wherein
each of the spiral channels has an inlet end for receiving melt from the feed bore and
an outlet end, a cross-sectional area of each of the spiral channels decreasing
continuously toward the outlet end.
8. The blowing head of claim 7, wherein the spiral channels are vertically superposed
by a number that is greater by one than the number of times each of the spiral channels
is angled upward.
9. The blowing head of claim 7, wherein a first segment of each of the spiral channels
connected to the feed bore is arranged directly at a sealing surface of the melt channel,
the sealing surface being arranged between said spiral mandrel and said outer casing,
whereby a space between the spiral channels and a bottom of the melt channel is
minimized.
10. The blowing head of claim 10, wherein a lower edge of the first segment of each
of the spiral channels lies on the same plane as said sealing surface.
11. The blowing head of claim 10, wherein said cylindrical mandrel includes a vertical
section under a lower edge of the first segment of each of the spiral channels and
adjoining the sealing surface for centering said cylindrical mandrel.

112
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Chapter Three

Analysis Procedures

117
1.Fill
1.1. ANSYS DESIGN MODELER - Basic Tutorial 06 - FILL - Negative Volume

It's very important the difference between caps and cavity and how to create a
surface in Ansys

1.2. Setup tutorial

parison extrusion simulation using Ansys Polyflow

It's better to fill the part using CATIA instead of ANSYS

Example of the die head

Based on the previous tutorial video Setup and after the modelling of the part Close
surface

118
2.Ansys Mesh

mesh

Skewness

This is the high level of skewness should

modified
be in the model

Take care during the meshing process with:

• Skewness value should beless 0.9

119
Aspect ratio

Review the values of the aspect ratio and the number of elements of Ansys

Number of elements

Tutorial

SimCafe: Crank in ANSYS, Element Skewness

120
2.1. Type and size

2.2. Statistics: (Skewness and aspect ratio)

121
Ansys Mesh

122
3.Aspect Ratio

Setup

Adjust the name on the surfaces

123
Create a new task

Screen clipping taken: 30-Dec-16 11:03 AM

124
To remove this notice,
wvisit:

125
4.Sub task

126
5.Domain

5.1. To set up
Then material selection in the domain
Then upper
Read an old material data file

127
Material data selection

Then select the isothermal material

128
Adjust the units

After selecting the material , we need to adjust the units

• Modify the system

Then ,
Select the new system (metric )

129
130
Adjust the gravity

The value should be -9810

131
6.Gravity

132
Inertia terms

Adjust that inertia will be taken into account

133
Inflow

Select fully developed

134
7.Flow boundary

7.1. Inflow properties

The value will be in mm3 /s in case of volumetric flow rate

So,
You should review the units before the value
WHEN USING MASS FLOW, THE CAPACITY kg/hr. should be
divided by (1000*60*60)
to be converted from g/s to kg /gr
Free surfaces
It should be selected in case of connected surface.
Used to show something like the die swell so we need to add a
volume and told Ansys that this volume is a free surface.
You should review the video.

135
Interpolation

Try first to be Picard but in the video it was Newton

Should be Newton

136
8.Global re-meshing

Used with 2D meshing

8.1. Transient iteration

8.2. Numerical parameter

Select upper level twice

137
9. Outputs

Then,
Select the modify the system of the units
Select the metric system
Then upper + upper

Select the number of steps to be 5

138
 Then select the upper level

Next step
Create a new task
Select No in the massage of coping the data
This are the parameters for the new task

Redefine the global parameters of a task

Then

139
Delete the task 2
Enter to task 1 agarin
Create a subtask
Select No
Select post processor
Rename the subtask
Then select the new subtask from tree
Then finalize the subtask
Number of processor
Write click on solution and select
Preference then select polyflow
Then select the number of processor and then update the solution

140
10.To review the solution system type

141
11.Important remarks for the die head flow analysis using Ansys aim
1. Using Ansys SCDM to extract volume
• From prepare select volume
• Then select the input and output edges
2. Analysis of die (flow inside the die) and add temperature to predict the temperature
distribution
3. When select the wall, select all surfaces except inlet and outlet
4. Must save before the analysis to allow the soft to use the hard with the ram
5. Analysis of the bolts, input 500 bar for big dies & 300 for small dies
6. Using transcript to check the analysis progress from the flow of analysis bar
7. Flow outlet must be in the Z direction

142
12.ANSYS AIM: Predicting Extrudate Shape Using a Polymer Extrusion Simulation

We will examine the flow of polymer melt as it is pushed or extruded through a three-
dimensional die as the polymer fluid is extruded out of the die. The free surface of the
extrudate is exposed and begins to deform. We will use the geometry that consists of
two connected bodies, a body that represents the fluid as it enters and is confined by
the die shown here in green and another body that represents the extrudate coming
into contact with air that could deform freely shown here in purple due to the
symmetrical nature of the actual die the geometry will use only represents a quarter
of the die, so we will be able to use symmetry conditions later in order to simplify the
calculations.

We will get started using the polymer extrusion template. Our goal is to calculate how
the extrudate deforms once it exits the die. I will choose the predict extrusion option
create the simulation and import the geometry once the simulation which is created.
I can see the imported geometry and the various tasks the template has created. I will
proceed to the mesh task. The template has already defined certain default setting. I
have made some adjustments to the setting to produce the better mesh.

143
I will update the mesh task to generate a computational mesh.

For this example, in the extrusion task, the template has already created a physics
region, physics options materials and fluid flow of physics conditions in the physics
region panel.

144
The template has used the bodies for the die and the extrudate to create a single
physics region with the polymer extrusion physics type selected in the material
assignment panel. You can change your material model from a Newtonian fluid to a
generalized Newtonian fluid if desired. For this example, we are using a generic
Newtonian polymer, so we will keep the default setting in the generic polymer
material panel. You can also assign a specific generalized viscosity material model. If
desired for this example, we have used the default settings for the generic Newtonian
polymer. For the sake of simplicity, we are using a Newtonian fluid that exhibits the
constant viscosity such a fluid leads to an important velocity arrangement at the dial
it and therefore two large extrusion deformations for this polymer extrusion
simulation.

145
The template has already created typical fluid flow physics conditions. I have already
set up the details for the various conditions. I have assigned this face to be the inlet
boundary with a specific volume flow rate.

I have assigned these faces to be a wall boundary with no slip that is the polymer fluid sticks
to the wall surface.

146
This face is assigned to be the extrudate exit condition where you can specify the
flow conditions at the exit. For this problem, we will keep the defaults of no fixed
edges and no forces

These phases are assigned to a free surface condition representing the open surface

And finally, this body is assigned to be the extrudate itself whose final shape will be
determined in the final solution

147
I need define two symmetry planes:
Here I have assigned these faces to be one symmetry boundary

And I have also assigned these faces to be another symmetry boundary

148
I can update the extrusion physics task to generate a solution. I will keep the default
solution settings as they are adequate for the present case as the problem is solved. I
can see the convergence of the main fields and quantities in the solution monitors
tab.
When the solution is complete, I can review the results of the simulation three
contour results objects and a vector result object have already been created as part
of the template. The contour results are for velocity magnitude, pressure and shear
rate.

After I update results tasks, I can review the results, I can review the results of each
object.
Here are the velocity magnitude contours:

149
The pressure contours:

The shear rate contours:

The vector results illustrate the velocity vectors in the flow field

We use velocity contours on the inlet and the extrudate exit surfaces to compare the
initial shape of the die and the extrudate with the final shape of extrudate.

150
The final cross-section of extrudate is different from the one of the die due to the
velocity rearrangement that occurs at the die lip within the die.

The velocity is higher at the center of the channel while it must be constant in the
extrudate where no force is applied the redistribution of matter induces deformation
this concludes this demonstration of setting up and solving a polymer extrusion
problem using same.

151
13.ANSYS AIM: Determining Die Lip Shape Using a Polymer Extrusion Simulation

In this demonstration you learn how to set up and solve an inverse polymer extrusion
problem in Ansys aim where we can examine the flow of a polymer melt as it is pushed
or extruded through a three-dimensional die. For this example, we will examine a type
of simulation called an inverse extrusion where we determine the shape of the
extrusion die based on the desired end profile shape of the extruded material. We will
use the geometry that consists of two connected bodies, a body that represents the
fluid as it enters and is confined by the die shown here in green and another body that
represents the extrudate coming into contact with air that could deform freely shown
here in purple due to the symmetrical nature of the actual die the geometry will use
only represents a quarter of the die, so we will be able to use symmetry conditions
later in order to simplify the calculations.

We will get started using the polymer extrusion template. Our goal is to predict the
shape of the die based on the current end profile shape of the extruded. We will
choose the determined die lip shape option create the simulation and import the
geometry once the simulation which is created. I can see the imported geometry and
the various tasks the template has created. I will proceed to the mesh task. The
template has already defined certain default setting. I have made some adjustments
to the setting to produce the better mesh.

152
I will update the mesh task to generate a computational mesh.

For this example, in the extrusion task, the template has already created a physics
region, physics options materials and fluid flow of physics conditions in the physics
region panel.

153
The template has used the bodies for the die and the extrudate to create a single
physics region with the polymer extrusion physics type selected in the material
assignment panel. You can change your material model from a Newtonian fluid to a
generalized Newtonian fluid if desired. For this example, we are using a generic
Newtonian polymer, so we will keep the default setting in the generic polymer
material panel. You can also assign a specific generalized viscosity material model. If
desired for this example, we have used the default settings for the generic
Newtonian polymer. For the sake of simplicity,
we are using a Newtonian fluid that exhibits the constant viscosity such a fluid leads
to an important velocity arrangement at the dial it and therefore two large extrusion
deformations for this polymer extrusion simulation.

The template has already created typical fluid flow physics conditions. I have already
set up the details for the various conditions. I have assigned this face to be the inlet
boundary with a specific volume flow rate.

154
I have assigned these faces to be a wall boundary with no slip that is the polymer
fluid sticks to the wall surface.

This face is assigned to be the extrudate exit condition where you can specify the
flow conditions at the exit. For this problem, we will keep the defaults of no fixed
edges and no forces.

155
These phases are assigned to a free surface condition representing the open surface.

And finally, this body is assigned to be the extrudate itself whose final shape will be
determined in the final solution

I need define two symmetry planes:

Here I have assigned these faces to be one symmetry boundary

156
And I have also assigned these faces to be another symmetry boundary

I can update the extrusion physics task to generate a solution. I will keep the default
solution settings as they are adequate for the present case as the problem is solved. I
can see the convergence of the main fields and quantities in the solution monitors tab.
When the solution is complete, I can review the results of the simulation three contour
results objects and a vector result object have already been created as part of the
template. The contour results are for velocity magnitude, pressure and shear rate.

After I update results tasks, I can review the results, I can review the results of each
object.

157
Here are the velocity magnitude contours:

The pressure contours:

The shear rate contours:

158
The vector results illustrate the velocity vectors in the flow field

Velocity contours on the inlet and the extrudate exit surfaces to compare the initial
shape of the die and the extrudate with the final shape of extrudate .

159
14.ANSYS AIM: Getting Started - Part 1
In this demonstration you learn about the simulation work flow in aim by walking
through a structural simulation of the effects of temperature inside a manifold. To
start we will choose the template app that matches the physics. We will be solving the
structural template.
In the initial step we will import in existing geometry. In next step select thermal
keeping all other defaults then click finish to start the simulation

The simulation is made up of distinct but connected steps and calls these tasks the
template creates the task of your simulation.
Here you can modify an imported geometry or even create a new geometry return to
the physics simulation by clicking here.

160
Next is the mesh task: let's review the set up in the mesh data panel how fine do we
want the mesh to be a good strategy especially for larger models is to begin with a
lower mesh resolution that calculates quickly and then if needed full again with a
higher mesh resolution you can always come back and refine the entire mesh or add
controls to refine specific areas of interest updating the mesh tasks generates the
mesh

161
The next task: we set up and solve the physics solution
In the physics task the physics region defines the physics being solved.
In this example structural and thermal, the location field shows that all bodies in the

model are part of the physics region.

Before you can update this task, the messages tab summarized the changes needed.

Here's a blue color cue to add structural conditions. You can add objects here in the
data panel.

162
Let's add supports to the openings of the manifold using the face selection filter. Use
the control key to select multiple locations at once to add faces or change a location

select the faces you want to include edit the support and add or replace the faces.

163
Right click to add a temperature condition and apply it to a selected set of faces on

the inside of manifold. The location is listed when you click inside the field.

Let's confirm that the material is structural steel.

164
We can also realistically render the model using the enhanced display.

Solve physics runs the calculation and updates the physics task information about
the solution.

You can visualize the simulation in the results task. The template automatically adds
three results.

165
Now updating the results task evaluates the results.

You can add more contours calculated values of vectors.

It is easy to animate any of the results and view them.

166
We've now completed a simulation. You may want to make refinements or changes
to the physics set up, the mesh or the model and solve again.

167
15.ANSYS AIM: Getting Started - Part 2
In this demonstration you learn about the Ansys aim workspace. you can start by using
a template app containing many of the defaults settings.

You will need this is how the workspace looks after you have imported your
geometry in a fluid flow template.
The summary grid shows the simulation tasks that were automatically added for this
template.

An end to end representation of these tasks is displayed in the workflow tab of the
view panel.

Using the workflow tab, you can easily manage the simulation process by right clicking
on a task to add, delete or duplicate a task.

168
Using the right click menu to add an object.

The property panel is displayed

Property panels define the minimum input requirements for a task and using them is
the fastest way to set up your simulation.
If you need more control beyond what the property panels offer.

169
The data panel gives you access to more typical properties and options to customize
your simulation and finally

Use color choose to communicate the simulation status red draws your attention to
items that must be completed to move forward yellow indicates that you need to
update the task and green confirms what the task is out to date.

170
You also notice that some buttons or menu items are highlighted in blue is a queue
for a suggested next step

In addition to color M communicates with you through messages progress indicators

and messages alerts display.

Missing data or potential errors are indicated with messages in both the property
and data panels alerts and messages are displayed in the messages tab.

By clicking on the link you navigate directly to the data panel where the change is
required you can also click on the status bar to display the corresponding messages
in the message tab. The transcript tab in the view panel displays text output from
solver charts specific to the physics type are displayed in the solution monitors tab.

171
These arrows behave like browser arrows so you can move backwards and forward
revisiting the objects you have already set up use a navigation bar to display a list of
properties within a given category. For example fluid flow conditions or jump to
specific objects in a task.

172
Let's demonstrate some of Em's graphic tools several tools are available to pick
specific components of the model with selection filters, for instance select only
bodies

Or only faces

Or see different views by hiding the edges or faces

Or making the model translucent

173
16.Multilayer procedures in Click 2 extrude
• Set up the part

Outlet 1

Outlet 2

Inlet 1

• Results Inlet 2

• Prepare the multilayer

174
 Profile 2

Profile 1

Organize as layer 1

Organize as layer 2
• Results (as a section)

175
Chapter Four

Troubleshooting

176
1.Flow lines appearing in blown film!
The customer saw lines appearing around the circumference of their blown film bubble
as represented by the image shown below.

They did not know what was causing the problem, and more importantly, how they could
fix it. They were under pressure to find a solution as it was affecting product quality and
making the product unacceptable for delivery.

1.2. What was the root cause?

Incorrect leakage flow and low shear stress!

The following image shows the path-lines, in 4 periodic sections, of a Spiral Mandrel
distribution system as predicted by the VEL™ Spiral Die module simulation.

177
 The channels and the gaps in the spiral mandrel and body were not designed
correctly for the polymer, and flow rates, that were being used. As a result, some
material from the adjacent spiral was leaking out too early and flowing backwards
down the previous spiral channel (as shown in the above image). Furthermore, the
shear stress in the first spiral channel was very low, which lead to stagnation and
degradation. The flow lines were a result of the “weld line” created by degraded
material where the flows from adjacent spirals would meet.

2.How it was solved?

Improve the design of the spiral distribution system!

Using the VEL™ Spiral Die module, we redesigned the spiral distribution system so that all
the path-lines continued in the same direction (with no back flow), as shown in the image
from the simulation below.

We also ensured that there was adequate shear stress at the walls to avoid material
stagnation and degradation. The optimized die was manufactured, installed and produced
acceptable product (without any flow lines).

178
 Bottom Line
This was a very challenging problem, for the customer, as there were many opinions as to the
cause of the problem. Investigating them all would be very costly and time consuming. Using
simulation, and our experience, we were able to quickly identify where the problem was
coming from and find a more direct solution, quickly and efficiently. Of course, the problem
(and the associate customer frustration) could have been avoided completely if proper flow
simulation was applied in the engineering phase of the equipment manufacturing process.
From <http://www.compuplast.com/case-studies/flow-lines-in-blown-film>

3.Excessive shear

• Excessive shear heating may lead to excessive screw wear

• Some reasons with corrective actions for the actual barrel temperature exceeding
the set point temperature are outlined below:
• Feed section is overfeeding. If the feed zone channel is too deep, more material may
be fed into the extruder than can be melted in the transition zone. Excessive shear
heat is generated at the entrance to the metering zone as un-melted solid is being
forced into the metering section.
• Mixing section is too tight. The gap between the mixer barrier flights and the barrel
wall in the mixing section is too small. The molten resin is forced through small gaps,
creating excessive shear heating, leading to significant barrel temperature override.

179
4.Blown Film Troubleshooting Guide (based on die head)
Problem Causes(s) Possible Solution(s)
Inconsistent melt feed to die Adjust temperature profile to provide for more uniform flow
Bubble Pull and clean the die examining for dirt, pelletized, or burnt
Dirty die Use purge material
matter
Instability
Misalignment Align nip rolls to die
Dirty die and/or die lips (foreign Clean die and/or lips with copper pad or brass shim
Die Lines matter lodged inside the die) Increase adaptor and die temperatures and screen mesh to
Insufficient blending of molten increase
Increase back pressure
mixing in extruder by adjusting barrel and die
polymer
Scratched die lips temperatures/Increase backshop
Repair surface at a machine pressure

Melt Fracture Inadequate die gap Increase die gap

Excessive friction at die lips Add processing aid to coat die lips and reduce COF
Increase melt temperature
Blocking Excessive surface treatment Reduce treatment level
Die lines Clean die lips
Contamination (degraded resin
or dirt lodged under edge of die Clean die lips, then reduce melt temperature
Splitty Film
lips which makes film split at
Thin
weld)spots in film Check for die concentricity
Extrusion temperature too high or Gradually adjust melt temperature
too low
Streaks Dirty die pin Clean pin/Add additive to die plate/Remove reclaim from die
Low
Gloss/ Poor mixing in extruder/die Increase mixing in the extruder
High
Haze Inconsistent melt feed to the die Check temperature settings
Adjust temperature profile to provide for a consistent melt
Dirty die Clean
feed die and/or die lips with copper pad or brass shim
Gauge
Improperly adjusted die Follow procedures for adjusting die bolts
Variations Misaligned die Center and align die to nip
Die heat variation Check for burnt out heater bands/Check temperature
Overtreatment Adjust to proper level of treatment
controllers
Poor Heat Seal Check die uniformity
Examine for defective heater bands
Gauge variations
Check for possible surging
Shark skin Extrusion temperature too low or Increase temperature or reduce temperature
Refer to two common type
too high Zig zag instability problems are remedied by reducing
defects consisting of highly interfacial shear stress by
irregular or something regular
Interfacial waviness which appears in co - increase the die gab
extruded structures at the
instability
polymer interface (internal
defect) which distinguishes it from
shark skin, is (a surface defect)

camber Non-uniform stress Review die design

180
5.Some typical extrusion problems
• Blown film quality and degradation
• Unstable co-extrusion process

5.1. Blown film quality and degradation

In some cases, there is sharp line on the product which is equal to the number of spirals.
There are 4 spirals, so there are 4 sharp lines and this is shown in following photo,

So we did an analysis spiral mandrel.

Here is the 3 D finite element simulation of the spiral mandrel flow field. In this
simulation, you can see pressure distribution and the final velocity distribution at the
exit. The pressure distribution is normal and velocity distribution looks uniform, so
there is nothing in this indicate the appearance of these lines.
So we analyze this with path lines,

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Here is four of those periodic sections put together and we put in a seed points at the
start of the spiral channel or along the circumference and we traced those path lines
out to the die exit as the following photo,

(3) (1) (2)

You can see here (1) that some path lines would flow backwards to the next spiral
section and the flow along here, so you can see for example this path line would go
straight along (2) and then come out. This path line will go straight along here and
come out but these three path lines here (1) would go back down the channel and
then come out in the previous section. As a result because there is back flow, we have
a region in each spiral section where the material is stagnant (in the following figure)
and so when the ultimate weld line is formed between the flows going in this direction
(3) and the back flow material. This weld line is produced with material that’s moving
slowly, has a very high residence time and as a result has a higher potential for
degradation. While it is sitting here in the die, it will have much longer residence time
in the die, so we want to avoid this back flow phenomenon.

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 Figure: stagnant region of material in each spiral section

We are designing the gun dies and this phenomenon by the way is almost as
impossible to see when you are looking at a metal die, you can't see the flow field.
When this happens, you might to be able to see it when you disassemble the die and
get a visual of some lines of the material.

5.2. Unstable co-extrusion process

The following figure shows film sample exhibiting (wave) instability in feed block co-
extrusion,

These waves appear also in co-extrusion blown film.

We want to analyze what would be the cause of this.
The following figure shows the product that was being produced (three layer
structure),

183
We have relatively thick skin layers and a very thin center layer which normally
wouldn’t cause a problem because the low stress region in any flow field is the
center area. This doesn’t happen really when the materials were all flowing together,
it happens at the merge point.
So we analyze the feed block of these systems.

This is a typical feed block geometry (the following figure),

If we do a cut down the center of this feed block (as the following figure) and analyze
that geometry section.

The following figure is a 2D finite element simulation of feed block geometry

showing the merging of three layers of materials.

184
The red color represents high velocity and blue represents low velocity.
It is noticed that this ascension layer has a maximal velocity prior the merging about
14.6 mm/s, but the once the streams are all together and just prior to entering the
die, the maximum velocity is about 64.6 mm/s, so what does this mean. This material
has to accelerate 4.4 times, so this is the acceleration ratio,
64.6
Central layer acceleration = = 4.4
14.6
This indicates the flow rate of material.
Whenever the polymer has to accelerate, you have to consider that to be like
stretching, so this is the shape (the following figure) that the middle layer occupies
prior to merge then at merge region due to the tapering of the veins. You see some
large above the layer shape and then the thinning down of that layer to its ultimate
final thickness.

So you can imagine this as the material being stretched at this point .

Depending on the material properties, the material may or may not like to be
stretched in that region, so this comes in this brings into play the property of
elongational or extensional viscosity.

185
Shear viscosity polymers have an elongation viscosity that is resistance to stretching
and certain polymers like HDPE or LLDPE have a continually decreasing elongational
viscosity. This means that the more you stretch them, the easier it is to stretch.
Some other polymers like branched LDPE or EVOH which is a highly oxidized LDPE,
these highly branched materials exhibit a strain hardening effect. As you stretch them,
they tend to stiffen up and resist that stretching.
When you take a rubber band and stretch it at some point, it doesn’t want to stretch
anymore and ultimately it breaks and this is what happens within the coextrusion
system when you have materials flowing together that like to stretch and material that
don’t like to stretch. You can exceed the stretch limit of these materials and tear them
within the flow field, so that they become discontinuous within the flow field.
If we look at the deformation rate along the middle layer (The following figure) so right
now we are taking a stream line along the center layer and the material when it is
flowing prior to the merge region, the velocity about 16 mm/s and then just prior to
the merge, you see that the channels open up so the material flows down and block
the black line. At (1) the material slows down and then it accelerates to its final velocity
of about 65 mm/s. The blue line corresponds to the scale on the right which is the
elongation rate. This material moves along with no elongation of zero condition and
then just prior to merge the channel, the channel opened up a little bit, so the material
slows down and this like compression or squeezing in the material and then rapid
stretching of the material, so we have a high elongation rate of 4.5 1/s.

We perform a simulation in a problem that we see and we correlate that problem to

this abrupt stretching of the material, so now when we want to propose a solution we

186
want to reduce the amount of stretching the material in the coextrusion field. So we
modify the geometry to perform more gradual stretching tear within the channel.
We can make the change as the following figure,

3
2

We can control over this angle (1), so we can make the change more gradual and then
we have pre-accelerated the material in the region (2). We also make a bit of
modification in region (3) to avoid slowing down. We don’t taper these out (4) and as
a result we have a better-balanced velocity of the materials. When they are coming in
the merge region, we have pre-accelerated this material. We still have the same final
condition because we want to match the same die geometry and we have the same
overall flow. Because of the pre-acceleration, the velocity ratio has reduced from 4.4
to 2.5 approximately half.
You can see this in the following shape that the layer occupies is the amount of space
that layer occupies in that section. There is less abrupt acceleration of the material or
stretching.

187
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