Learning Forum

[anthony.broadhead]

Discover AIM extrusion "   Predict Die Lip Shape " 

The model has meshed successfully and the extrusion parameters have been entered successfully, but the error messages shown in the attached file have stooped the solver completing the simulation. This simulation has run and soled OK before, but in this instance a small restriction to the flow has been to the pre-land  of the die, shown in the attached file.

 

          Tony. Broadhead.

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[Gaurav Sharma]

Hi Tony Broadhead

Is it possible to share the model with us for reproducing the error and further debugging.

Thanks &Regards,

Gaurav

[anthony.broadhead]

Hi Gaurav,

          Thank you for your quick response, please see the attached model as requested.

 

                     Tony.

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[Gaurav Sharma]

Tony Broadhead 

Can you please share the simulation files (.wbpz model)

[anthony.broadhead]

Gaurav_ANSYS 

  Sorry Gaurav,

 

              I sent you the wrong file try this on.

                           Tony.

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[anthony.broadhead]

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[anthony.broadhead]

Tony Broadhead 

[Gaurav Sharma]

Hi Tony Broadhead

I looked into your model and it seems the wall conditions are not meeting a couple of requirements specified for the lateral BCs

1. There should be atleast thre lateral non over lapping boundary conditions
2. The polymer extrusion solver implicitly assumes that the shape of the inlet and outlet sections are very similar (ideally, they should initially overlap) and the finite element faces of the lateral boundaries are perpendicular to the direction of extrusion. Also note that the polymer extrusion solver performs a check to see if the lateral faces have an angle greater than 60° with the direction of extrusion.

Please refer the help manual here for details.

I would suggest to split you wall BCs such that there are atleast 3 such conditions and also make necessary changes to your geometry.

I hope this will resolve the issue.

Thanks & Regards,

Gaurav

[anthony.broadhead]

Gaurav_ANSYS 

Hi Gaurav,

           I am a bit of a novice at extrusion simulation, so please bear with me, but can you explain what the 

BCs are. I split the model into four separate bodies in Space-claim and made three shared faces at the interfaces, as in all my current simulations. "Inlet" and "outlet" sections are you referring to the Die, Pre-Land,    and Land faces. " Angle greater than 60° with the direction of extrusion" Does this suggest that the restriction section I have added to bottom of the pre-land area of the die cannot be meshed or solved. Can this be achieved in Polyflow software

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[anthony.broadhead]

Hi Gaurav,

           I am a bit of a novice at extrusion simulation, so please bear with me, but can you explain what the 

BCs are. I split the model into four separate bodies in Space-claim and made three shared faces at the interfaces, as in all my current simulations. "Inlet" and "outlet" sections are you referring to the Die, Pre-Land,    and Land faces. " Angle greater than 60° with the direction of extrusion" Does this suggest that the restriction section I have added to bottom of the pre-land area of the die cannot be meshed or solved. Can this be achieved in Polyflow software

[anthony.broadhead]

Tony Broadhead .

 Hi Gaurav,

  Do you have any answer's for me as I am struggling to make any changes to the velocities of the extrudate at      the die lip, by changing the geometry of the Pre-Land.

       Thanks Tony

[Gaurav Sharma]

Tony Broadhead 

Hi Tony,

I am discussing the problem with the expert and will get back to you with refined suggestions soon. Thanks for your patience.

Regards,

Gaurav

[anthony.broadhead]

Thanks Gaurav

[Gaurav Sharma]

Tony Broadhead 

Hi Tony,

I could figure out that the problem in your model is due to the tapered region which you have opted as "Die Deformation 2" and the deformation type is set to variable. As discussed earlier, the polymer extrusion solver implicitly requires that the shape of the inlet and outlet sections are very similar (ideally, they should initially overlap), which is not the case with your model and hence the problem.

Hence, this part is complex in geometry and is not suitable to be used as a die region for inverse extrusion problem. I have made some changes in the model to make it working:

1. Introduced a new Die deformation 2 region which is same in shape as Die deformation 1.
2. Extended the length of Extrudate.

With these changes, the setup is more inline with what inverse extrusion problem requires. Attached is the file, you make use this as a reference and make necessary changes at your end. Hope you find it seful.

Thanks & Regards,

Gaurav

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[anthony.broadhead]

Thanks Gaurav,

 Unfortunately the download of the Corrected mode. wbpz file failed. you could try sending again,

or may be you could send a number of screen shots, highlighting the mods you have done.

    Tony.

[Gaurav Sharma]

Tony Broadhead 

I have shared the model with you over email using securetransfer link. please check your inbox.

Regards,

Gaurav

[anthony.broadhead]

Gaurav_ANSYS .

 Hi Gaurav,

 The file failed to download so I tried again and it seemed to be successful, but whrn

 I tried to open the Zip file " Corrected mode. wbpz error messages where displayed.

Please see the attached file for details.

 

                 Tony.

🛈 This post originally contained file attachments which have been removed in compliance with the updated Ansys Learning Forum Terms & Conditions

[Gaurav Sharma]

Tony Broadhead 

This looks like a separate error and not related to the the file I shared in particular. Can you please confirm if you are able to open other AIM models or a fresh AIM session on your machine.

[anthony.broadhead]

Hi Gaurav,

     Yes I can still open standard models in the wbpj. file format, and a new session

      in AIM.

 

                Tony.

[Gaurav Sharma]

Tony Broadhead 

You have to open the wbpz in the same way you open a wbpj (Goe to AIM window --> File --> open and select the wbpz file I shared). AIM will prompt you to save the model in wbpj format immediately as you open a wbpz file. If you are trying to unzip the wbpz, thats not the intended way to use wbpz (AIM archive) file.

Please let me know if the isue still persists.

Regards,

Gaurav

[anthony.broadhead]

Gaurav_ANSYS ,

 Hi Gaurav,

    Sorry about that I think you are correct, but unfortunately you have saved the file  in a later version of AIM          to the one I am running.

     I don't suppose you received the file I tried to send you regarding the other issue I have with viewing the            change in velocities at the die lip. By manipulating the geometry behind the lip only.

 

               Tony.

[Gaurav Sharma]

Tony Broadhead 

Yes, I saved it with 2019R3. Anyways, here is the snapshot of changes I incorporated in your original setup.

 

Please give it a try and let me know if you seek any further clarification.

Thanks & Regards,

Gaurav

[anthony.broadhead]

Gaurav_ANSYS ,

Thanks Gaurav,

   Which section contains the cutout or insert.

  Please show a view on the bottom faces of the model

            Tony

[Gaurav Sharma]

Tony Broadhead 

The additional section I added doesnt contain any cutout and its just an extension of extrudate geometry. This is to keeping in my mind the constraints on the die section we discussed earlier for an inverse extrusion problem.

 

Regards,

Gaurav

[anthony.broadhead]

Thanks Gaurav,

  That,s great, just what I thought, but I needed to make sure.

  If you could get me an answer on the subject of velocities, it would be much appreciated, as this output from AIM is the main criteria on which we are going to base the design our dies on. At this moment in time anyway.

 

                Tony.

[Gaurav Sharma]

Tony Broadhead 

Sorry I missed to respond about your other query. yes, I haven't received the files yet for further debugging. can you please share them soon so that i can start debugging.

Regards,

Gaurav

[anthony.broadhead]

Gaurav_ANSYS 

Hi Gaurav,

   I have tried to send you the files, but I cannot  get them to upload.

               Tony.

[Gaurav Sharma]

Tony Broadhead 

I have shared a securetransfer link with you. Please check your inbox and use the same to send the required files in wbpz format

Regards,

Gaurav