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5D Axisymmetric Extrusion
1.1. Introduction
This tutorial illustrates the setup and solution of a 2.5D axisymmetric extrusion problem. The problem
corresponds to a simplified 2D simulation of a swirling flow that occurs around the head of an extrusion
screw. The fluid is forced through the die and exits the +extruder after a short die land. The model in-
volves a free surface, the position of which is unknown.
Create a sub-task.
Set material properties and boundary conditions for a 2.5D axisymmetric extrusion problem.
1.2. Prerequisites
This tutorial assumes that you have little experience with Polyflow and its associated modules.
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2.5D Axisymmetric Extrusion
Since the problem involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain, as shown in Figure 1.2: Subdomains and
Boundary Sets for the Problem (p. 3)
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Problem Description
The boundary sets for the problem are also shown in Figure 1.2: Subdomains and Boundary Sets for the
Problem (p. 3), and the conditions at the boundaries of the domains are:
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2.5D Axisymmetric Extrusion
1.4. Preparation
To prepare for running this tutorial:
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
4. Narrow the results by using the filter on the left side of the page.
7. Unzip the 2.5-Axi-Extrusion_R150.zip file you have downloaded to your working folder.
8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.
Note
If you create the mesh in GAMBIT or a third-party CAD package, you need to convert it before
you read it into Polydata. In this tutorial, the mesh file has already been converted. So you
can read the mesh file directly into Polydata.
1. Create a Fluid Flow (Polyflow) analysis system by drag and drop in ANSYS Workbench.
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Step 1: Project and Mesh
a. Rename the project name to Tutorial 1 by double-clicking and editing the text Fluid Flow
(Polyflow).
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2.5D Axisymmetric Extrusion
a. Select ext2d.msh.
b. Click Open.
3. Double-click the Setup cell to start Polydata and read in the mesh. When Polydata starts, the Create a
new task menu item appears in bold text, and the geometry for the problem is displayed in the Graphics
Display window.
Note
At this point (when Create a new task appears in bold text) if you realize that you have
read the wrong mesh file, click STOP at the top of the Polydata menu and repeat the
process to access the correct mesh file.
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Step 2: Models
F.E.M. task
Steady-state problem(s)
The Current setup (above the selected options) will be updated to reflect the selection. In any
problem solved using Polyflow, first an F.E.M. task is defined to calculate the flow field. If inform-
ation regarding the trajectories is necessary, specify a MIXING task after solving the problem
with the F.E.M. task specification and obtaining the results file. Then solve the problem once
again. 3D velocity components (u,v,w) are prescribed in a 2D cylindrical reference frame (r,z), so
2D 1/2 axisymmetric geometry has been chosen. A steady-state condition is assumed for this
problem.
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2.5D Axisymmetric Extrusion
Note
At this point (when Create a sub-task appears in bold text) if you realize that you
have made a mistake in the creation of the task and you need to return to that menu,
do the following:
ii. Select Redefine global parameters of a task and make the necessary changes.
iii. Click Accept the current setup when you are satisfied with the corrected settings.
Create a sub-task
Note
At this point (when Domain of the sub-task appears in bold text) if you realize that
you have made a mistake in the creation of the sub-task and you need to return to
that menu, do the following:
ii. Select Redefine global parameters of a sub-task and make the necessary changes.
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Step 3: Material Data
Since this flow involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain. Here, the sub-task applies to both
subdomains (the default condition).
Accept the default selection of both subdomains by clicking Upper level menu.
Material data
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2.5D Axisymmetric Extrusion
where:
= shear rate
Modify fac
Modify tnat
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Step 4: Boundary Conditions
Modify expom
6. Check whether the values of the constants are correct, and repeat the previous steps if you need to
modify the constants again.
7. Click Upper level menu three times to leave the Material Data specification.
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2.5D Axisymmetric Extrusion
a. Select Zero wall velocity (vn=vs=0) along BS_1 and click Modify.
b. Click Inflow.
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow. In this case, Polydata will use a 1D finite-element technique to compute a 1D fully-developed
velocity profile, based on the specified material properties and flow rate. Moreover, the inflow
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Step 4: Boundary Conditions
boundary condition requires that the computational domain be built in such a way that the basic
assumptions of fully-developed flow are satisfied. In axisymmetric geometries, the inflow section must
be perpendicular to the axial direction.
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid is that
of the solid surface. This is commonly known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and therefore has no velocity relative to the wall.
Retain the default condition Zero wall velocity (vn=vs=0) along BS_2.
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid
particles go out of the domain through the free surface. This constraint is called the kinematic
condition, v_n = 0. This equation requires an initial condition at the starting point of the free surface,
which in this case is located at the intersection of BS_2 and BS_3.
a. Select Zero wall velocity (vn=vs=0) along BS_3 and click Modify.
Note
Do not select the Outlet option. It is only applicable for die design problems.
As mentioned above, the starting point of the free surface is at the intersection of BS_2 and BS_3.
h. Retain the default settings for the Normal force and Direction of motion.
j. Click Upper level menu to return to the Flow boundary conditions menu.
It is reasonable to consider that a uniform velocity profile is obtained at the exit. In most cases, a bulk
flow is obtained and thus no force is acting, so the selection of zero normal and tangential forces is ap-
propriate. In situations involving pulling velocity or force or gravity, the corresponding boundary condition
should be selected.
a. Select Zero wall velocity (vn=vs=0) along BS_4 and click Modify.
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2.5D Axisymmetric Extrusion
c. Accept the default value of 0 for the normal force by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force by clicking Upper level menu.
5. Retain the default condition at the symmetry axis (Axis of symmetry along BS_5).
For axisymmetric models, the axis of symmetry is always the y axis. Polydata determines the axis of
symmetry from the mesh file, and automatically imposes the symmetry condition along the line r=0
(x=0).
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Step 4: Boundary Conditions
Since the screw is rotating with angular velocity = 2 = 6.2832 rad/s, the rotational velocity along this
boundary is prescribed to increase linearly with ( = 6.2832 ). In the equation for , X denotes the
direction and Y denotes the direction. Since the fluid sticks to the wall, = 0 = .
a. Select Zero wall velocity (vn=vs=0) along BS_6 and click Modify.
c. Accept the default value of 0 for the normal velocity ( ) and tangential velocity ( ) by selecting
Upper level menu twice.
e. Click Velocity w imposed and select 'w' velocity = linear function of coordinates.
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2.5D Axisymmetric Extrusion
g. Enter 6.2832 as the New value for the constant B and click OK.
j. Click Upper level menu at the top of the Flow boundary conditions menu.
Global remeshing
In some cases, when the mesh is geometrically complex, it may be necessary to split it into additional
subdomains in order to define a specific remeshing method on each of them. For this purpose, Polydata
allows you to create several local remeshings. For the current problem, a single local remeshing is sufficient.
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Step 5: Remeshing
SD_1 is moved from the top list to the bottom list, indicating that only SD_2 will be remeshed.
If you accidentally remove the wrong subdomain, select it and click Add to restore it. Then, follow
the instructions to remove the correct subdomain.
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The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface. Mesh nodes are organized along lines of
remeshing (spines), which are collections of nodes logically arranged in a one-dimensional manner. This
technique is most suited for 2D extrusion problems. Polydata requires the specification of the first and
last spines that the fluid encounters (inlet of spines and outlet of spines, respectively).
In this case, the inlet of spines is the intersection of subdomain 2 with subdomain 1, and the outlet of
spines is the intersection of subdomain 2 with the flow exit (boundary 4).
Method of Spines
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Step 6: Stream Function
At this point, if you realize that you have made a mistake in global remeshing, click die swell at the
bottom of the menu and perform this Step again.
1. Select Condition on the stream function for field 1. Click No in the window that pops up.
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2.5D Axisymmetric Extrusion
If you have made a mistake in assigning the stream function, click F.E.M. Task 1 to get into that menu
and then repeat this Step.
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Step 8: Save the Data and Exit Polydata
Outputs
2. Accept the default output option for CFD-Post by clicking Upper level menu.
When exiting the menu, Polydata asks you to confirm the current system units and fields that are to be
saved to the results file for postprocessing.
If you do not enter the menu Outputs, Polydata will ask you to confirm the current system units at
the end of the session, if it is a new session.
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2.5D Axisymmetric Extrusion
If this was not yet done before (see above), Polydata asks you to confirm the current system units. It will
also ask to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
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Step 10: Postprocessing
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update from the shortcut
menu.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
ANSYS Workbench opens the View listing file panel, which displays the listing file.
b. In the View listing file panel, disable the Show only last 200 lines option and click the Manual
refresh button. Then find the SOLVER section that relates to F.E.M. Task 1; at the end of this
section, a message Convergence assumed is displayed. This indicates that the solution has con-
verged. See the Polyflow User's Guide for more information on convergence.
1. Double-click the Results cell in the ANSYS Workbench analysis and read the results files saved by Polyflow.
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2.5D Axisymmetric Extrusion
ANSYS CFD-Post reads the solution fields that were saved to the results file.
a. Right-click a blank area anywhere in the graphical window, and select Predefined Camera from the
shortcut menu, and select View From +Z.
The central mouse button allows you to zoom in and zoom out. The left mouse button allows rotating
the image. The right mouse button allows you to translate the image.
b. Also, right-click a blank area anywhere in the graphical window and deselect Ruler, if needed.
a. Click the Insert menu and select Contour or click the Contour button ( ).
b. Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
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Step 10: Postprocessing
c. In the details view for Contour 1, specify the following settings under Geometry:
i. Next to Locations, click the ellipsis button ( ) on the right and select SD_1_surf and SD_2_surf
(use Ctrl to select multiple items).
ii. Select PRESSURE from the Variable drop-down list, or click the ellipsis button ( ) on the right
and select PRESSURE.
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2.5D Axisymmetric Extrusion
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Step 10: Postprocessing
The details view of Default Transform will open below the Outline tab.
ii. In the details view of Default Transform, disable Instancing Info From Domain.
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2.5D Axisymmetric Extrusion
i. Click the Insert menu and select Text or click the button.
ii. Click OK to accept the default name (Text 1) and open the details view below the Outline tab.
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Step 10: Postprocessing
iii. In the Definition tab of the details view, enter Polyflow Results for Text String.
v. Click Apply.
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2.5D Axisymmetric Extrusion
a. Deselect Contour 1.
b. Click the Insert menu and select Vector or click the Vector button ( ).
c. Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
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Step 10: Postprocessing
i. In the Geometry tab, click the ellipsis button ( ) next to Locations, select SD_1_surf and
SD_2_surf (use Ctrl to select multiple items), and click OK.
ii. Select VELOCITIES from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select VELOCITIES.
iv. Define the attributes of vectors: in the Symbol tab, set Symbol to Arrow3D and Symbol Size to
5.
v. Click Apply.
i. On the Outline tab, under User locations and plots, deselect the item Text 1 previously defined.
The velocity vectors take all components of the velocity into account. Along the screw tip, the rota-
tional component is important, leading to long vectors that are not in the xy plane (perspective view).
After the die exit, a rearrangement of the velocity field takes place. The flow slows down along the
axis of symmetry and accelerates on the outside. This makes the particles go toward the free surface,
creating the swelling.
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2.5D Axisymmetric Extrusion
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Step 10: Postprocessing
ii. Under Render tab, deselect Show Faces and select Show Mesh Lines.
iii. Under Color tab, click the ellipsis ( ), select the color white and click OK.
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2.5D Axisymmetric Extrusion
i. Move the mouse to the left-hand border of the graphic window until the cursor suggests a rotation
along a vertical line.
ii. Left-click and move the mouse slowly to the right-hand side.
1.15. Summary
This tutorial demonstrated how to set up and solve a 2.5D axisymmetric extrusion problem. It showed
how to set up a free surface problem and the associated remeshing, and demonstrated the use of CFD-
Post to examine the flow behavior associated with the problem.
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