Polyflow Extrusion WS04 3D Extrusion

Chapter 4: 3D Extrusion
4.1. Introduction
This tutorial illustrates the simulation of a 3D extrusion process. Due to the velocity rearrangement that
occurs at the die exit, the shape of the extrudate is usually different from the die lip cross section.
Polyflow is capable of handling 3D free surfaces, so it can predict the extrudate shape that corresponds
to a given die geometry under prescribed operating conditions.
In this tutorial you will learn how to:
Create a sub-task to define a 3D extrusion problem.
Set material properties and boundary conditions for a 3D extrusion problem.
Select a remeshing method.
4.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. ?). Some steps in the set up procedure
will not be shown explicitly.
4.3. Problem Description

This problem deals with the flow of a Newtonian fluid through a three-dimensional die. Due to the
symmetry of the problem (the cross section of the die is a square), the computational domain is defined
for a quarter of the geometry and two planes of symmetry are defined.
The melt enters the die as shown in Figure 4.1: Problem Description (p. 1) at a flow rate of = 10
3
cm /s (a quarter of the actual flow rate) and the extrudate is obtained at the exit. At the end of the
computational domain, it is assumed that the extrudate is fully deformed and that it will not deform
any further. It is assumed that subdomain 2 is long enough to account for all the deformation of the
extrudate.
Figure 4.1: Problem Description
Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 1
3D Extrusion
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two subdomains (as shown in Figure 4.1: Problem Description (p. 1))
so that the remeshing algorithm can be applied only to the portion of the mesh that will be deformed.
The subdomain 1 represents the die where the fluid is confined. The subdomain 2 corresponds to the
extrudate that is in contact with the air and can deform freely. The main aim of the calculation is to
find the location of the free surface (the skin of the extrudate).
The boundary sets for the problem are shown in Figure 4.2: Boundary Sets for the Problem (p. 2), and
the conditions at the boundaries of the domains are as follows.
boundary 1: flow inlet, volumetric flow rate = 10 cm3/s
boundary 2: zero velocity
boundary 3: symmetry plane
boundary 4: symmetry plane
boundary 5: free surface
boundary 6: flow exit
Figure 4.2: Boundary Sets for the Problem
4.4. Preparation
To prepare for running this tutorial:
1. Prepare a working folder for your simulation.
2 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 2: Models
2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3. Enter the name of this tutorial into the search bar.
4. Narrow the results by using the filter on the left side of the page.
a. Click ANSYS Polyflow under Product.
b. Click 15.0 under Version.
5. Select this tutorial from the list.
6. Click Files to download the input and solution files.
7. Unzip the 3D-Extrusion_R150.zip file you have downloaded to your working folder.
The mesh file ext3d.msh can be found in the unzipped folder.
8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.
4.5. Step 1: Project and Mesh

1. Create a Fluid Flow (Polyflow) analysis system by drag and drop in Workbench.
2. Save the ANSYS Workbench project using File Save, entering 3D-extrusion as the name of the
project.
3. Import the mesh file (ext3d.msh).
4. Double-click the Setup cell to start Polydata.
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
4.6. Step 2: Models

In this step, first define a new task representing the 3D steady-state model. Then define a sub-task for
the isothermal flow calculation.
1. Create a task for the model.
Create a new task
a. Retain the following (default) options:
F.E.M. task
3D Extrusion
Steady-state problem(s)
This problem is a 3D simulation of the extrusion process, that is, a three-dimensional geometry is
assumed for the die. A Cartesian (x,y,z) reference frame is used for the 3D calculations. A steady-
state condition is assumed for the problem.
b. Click Accept the current setup.
The Create a sub-task menu item is highlighted.
2. Create a sub-task for the isothermal flow.
Create a sub-task
a. Select Generalized Newtonian isothermal flow problem.
A panel appears asking for the title of the problem.
b. Enter 3D die swell as the New value and click OK.
The Domain of the sub-task menu item is highlighted.
3. Define the domain where the sub-task applies.
Since this problem involves a free surface, the domain is divided into two subdomains; one for the region
near the free surface (subdomain 2) and the other for the rest of the domain (subdomain 1). In this
problem, the sub-task applies to both subdomains, which is the default condition.
Domain of the sub-task
Step 3: Material Data
Accept the default selection of both subdomains (SUBDOMAIN_1 and SUBDOMAIN_2) by clicking
Upper level menu.
The Material data menu item is highlighted.
4.7. Step 3: Material Data

Polydata indicates which material properties are relevant for the sub-task by graying out the irrelevant
properties. In this case, viscosity, density, inertia terms, and gravity are available for specification. For this
model, define only the viscosity of the material.
Material Data
1. Click Shear-rate dependence of viscosity.
2. Click Cross law.
The Cross law exhibits shear-thinning (the decrease in viscosity as the shear rate increases) that is a
characteristic of many polymers. The viscosity in this tutorial is given by the Cross law:
(4.1)
where:
= zero shear-rate viscosity = 85000
= natural time = 0.2
3D Extrusion
= Cross law index = 0.3
= shear rate
3. Specify the value .
Modify fac
Enter 85000 as the New value and click OK.
4. Specify the value for .
Modify tnat
Enter 0.2 as the New value and click OK.
5. Specify the value for .
Modify expom
Step 4: Boundary Conditions
Enter 0.3 as the New value and click OK.
6. Select Upper level menu three times to return to the 3D die swell menu.
The Flow boundary conditions menu item is highlighted.
4.8. Step 4: Boundary Conditions

In this step, set the conditions at each of the boundaries of the domain. When a boundary set is selected, its
location is highlighted in red in the graphics window.
Flow boundary conditions
1. Set the conditions at the flow inlet (BOUNDARY_1).
3D Extrusion
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b. Click Inflow.
c. Retain the default settings, Automatic and Volumetric flow rate.
d. Click Modify volumetric flow rate.
Enter 10 as the New Value and click OK.
When the Automatic option is selected, Polydata automatically chooses the most appropriate
method to compute the inflow condition.
e. Click Upper level menu.
2. Retain the default condition Zero wall velocity (vn=vs=0) along BOUNDARY_2 at the wall of SUBDO-
MAIN_1 (BOUNDARY_2).
At a solid-liquid interface, the velocity of the liquid is that of the solid surface. Hence the fluid is assumed
to stick to the wall. This is known as the no-slip assumption because the liquid is assumed to adhere
to the wall, and hence, has no velocity relative to the wall.
By default, Polydata imposes = = 0 along all boundaries. No action is required to accept the default
condition.
3. Set the conditions at the first symmetry plane (BOUNDARY_3).
In 2D axisymmetric problems, the axis of symmetry is automatically identified by Polydata, but for 3D
flows, you must manually identify a plane of symmetry.
The normal velocity ( ) and the tangential force ( ) are set to zero on a symmetry plane. A particle
cannot cross the plane ( = 0) due to the symmetry, so the particles flow at the same velocity on both
sides of the symmetry plane, leading to a zero tangential force.
b. Click Plane of symmetry (fs=0, vn=0).
4. Set the conditions at the second symmetry plane (BOUNDARY_4).
Step 5: Remeshing
b. Click Plane of symmetry (fs=0, vn=0).
5. Set the conditions at the free surface (BOUNDARY_5).
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, vn =
0. This equation requires an initial condition, that is, the starting line of the free surface. In the current
problem, the starting line of the free surface is the intersection of boundary 2 and boundary 5 (see Fig-
ure 4.2: Boundary Sets for the Problem (p. 2)).
b. Click Free surface.
c. Click Boundary conditions on the moving surface.
d. Select No condition along BOUNDARY_2 and click Modify.
e. Select Position imposed.
f. Click Upper level menu.
g. Click Upper level menu to return to the Kinematic condition menu.
h. Click Upper level menu to return to the Flow boundary conditions panel.
6. Set the conditions at the flow outlet (BOUNDARY_6).
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any ex-
ternally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
b. Click Normal and tangential forces imposed (fn, fs).
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.
e. Click Upper level menu at the top of the Flow boundary conditions panel.
4.9. Step 5: Remeshing

This model involves a free surface, the position of which is unknown. A portion of the mesh is affected by
the relocation of this boundary. Hence a remeshing technique is applied on this part of the mesh. The free
surface is entirely contained within subdomain 2, and hence only subdomain 2 will be affected by the relo-
cation of the free surface.
Global remeshing
1. Specify the region where the remeshing is to be performed (SUBDOMAIN_2).
3D Extrusion
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 suffi-
cient.
1st local remeshing
a. Select SUBDOMAIN_1 and click Remove.
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
b. Click Upper level menu.
2. Define the parameters for the remeshing method.
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, since a part of the mesh is deformed. For 3D
extrusion problems where large deformations of the extrudate are expected, the optimesh remeshing
technique is recommended
The optimesh remeshing technique requires the direction of extrusion to be parallel to the , , or
axis, and all slices into which the remeshing domain is cut must be perpendicular to the extrusion axis.
The domain to be remeshed is cut into a series of 2D slices (planes) in a direction perpendicular to the
direction of extrusion, and each plane is remeshed independently. For this process, Polyflow requires
the selection of the initial plane and the final plane. In this problem, the initial plane is the intersection
Step 5: Remeshing
of subdomain 2 with subdomain 1, and the final plane is the intersection of subdomain 2 with the flow
exit (boundary 6).
Optimesh-3D (extrusion only)
a. Specify the initial plane for the optimesh remeshing technique, by selecting Intersection with
SUBDOMAIN_1 and clicking Confirm.
b. Specify the final plane for the optimesh remeshing technique, by selecting Intersection with
BOUNDARY_6 and clicking Confirm.
3D Extrusion
Polydata asks whether you want to use the surface kinematic condition.
c. Click Yes to use the line kinematic condition.
The line kinematic condition is recommended for extrusion problems, and should be used in
combination with the optimesh remeshing technique.
d. Click Upper level menu three times.
The top-level Polydata menu is displayed.
4.10. Step 6: Save the Data and Exit Polydata

After defining your model in Polydata, you need to save the data file. In the next step, you will have to read
this data file into Polyflow and calculate a solution.
Step 7: Solution
Save and exit
Polydata asks you to confirm the current system units and fields that are to be saved to the results file for
postprocessing.
1. Specify the system of units for the simulation.
a. Click Modify system of units.
b. Select Set to metric cm/g/s/A+Celsius
c. Click Upper level menu twice.
Polydata asks you to confirm fields that are to be saved to the results file for postprocessing.
2. Click Accept.
This confirms that the default Current field(s) are correct.
3. 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).
4.11. Step 7: Solution

In this step, run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
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).
2. Check for convergence in the listing file.
a. Right-click the Solution cell and select Listing Viewer....
3D Extrusion
Workbench opens the View listing file panel, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the
following printed at the bottom of the listing file:
The computation succeeded.
4.12. Step 8: Postprocessing

Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results cell in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2. Display the velocity distribution on the boundaries.
a. Click the Insert menu and select Contour or click the button.
b. Click OK to accept the default name (Contour 1) and display the details view below the Outline
tab.
c. In the Outline tree tab, under User Locations and Plots, deselect Wireframe.
d. Perform the following steps in the details view of Contour 1:
i. In the Geometry tab, click the button next to Locations.
ii. Select all topological entities under PFL in the Location Selector dialog box (use Shift) and
click OK.
Step 8: Postprocessing
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
iv. In the Render tab, deselect Show Contour Lines.
v. Click Apply.
In Figure 4.3: Contours of Velocity Magnitude (p. 15), the velocity is zero along the die wall (as expected)
and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity profile changes
to become constant throughout the extrudate cross section. The transition between these two states
can be seen in the beginning section of the extrudate.
Figure 4.3: Contours of Velocity Magnitude
3. Display contours of velocity in cross sections.
a. Deselect Contour 1 in the Outline tree tab under User Locations and Plots.
3D Extrusion
b. Create the cross section planes, at Z = 0, 0.08, 0.15, 0.45 m.
i. Select Plane from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
iii. In the Geometry tab of the details view of Plane 1, select XY Plane from the Method drop-
down list.
iv. Enter 0 for Z.
v. Click Apply.
vi. Repeat steps 3.b.i.v. for the other planes, at Z = 0.08, 0.15, and 0.45 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
c. Click the Insert menu and select Contour or click the button.
d. Click OK to accept the default name (Contour 2) and display the details view below the Outline
tab.
e. In the Outline tree tab under User Locations and Plots, select Wireframe.
f. Perform the following steps in the details view of Contour 2:
i. In the Geometry tab, click the button next to Locations.
3D Extrusion
ii. Select all planes under User Locations and Plots (use Shift for multiple selection).
iii. Click OK.
iv. Select VELOCITIES from the Variable drop-down list (or click ).
v. In the Render tab, deselect Show Contour Lines.
vi. Click Apply.
Velocity profiles at the flow inlet, the flow outlet, and planes just before and just after the die exit are
displayed (Figure 4.4: Velocity Profiles at Cross Sections (p. 19)). Compare the velocity profile within the
die to the velocity profile just after the die exit at the end of the computational domain. In the die the
flow is fully developed. The velocity profile is flat in the extrudate, far away from the die exit; all the
particles in the cross section plane are at the same velocity. Just beyond the die exit, in the transitional
zone, the velocity profile is reorganized. The velocity profile on the plane = 15 is no longer fully de-
veloped, but it is not yet flat either. The velocity rearrangement is the source of the deformation of the
extrudate.
Figure 4.4: Velocity Profiles at Cross Sections
4. Compare the cross section shape of the extrudate with die.
a. Simplify the display.
In the Outline tree tab, under User Locations and Plots, deselect Contour 2 and Wireframe.
b. Display the die shape using a polyline.
i. Select Polyline from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
3D Extrusion
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method
drop-down list.
iv. Click next to Boundary List and select SUBDOMAIN_1_BOUNDARY_2, SUBDO-

MAIN_1_BOUNDARY_3, SUBDOMAIN_1_BOUNDARY_4 (use Shift for multiple selection).
Click OK to close the Location Selector dialog box.
v. Select SUBDOMAIN_1_BOUNDARY_1 from the Intersect With drop-down list.
vi. Under the Color tab, click next to Color and select dark blue.
vii. Click Apply.
c. Display the extrudate shape using a polyline.
i. Select Polyline from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method
drop-down list.
iv. Click next to Boundary List and select SUBDOMAIN_2_BOUNDARY_3, SUBDO-

MAIN_2_BOUNDARY_4, SUBDOMAIN_2_BOUNDARY_5 (use Shift for multiple selection).
v. Select SUBDOMAIN_2_BOUNDARY_6 from the Intersect With drop-down list.
vi. Click Apply.
d. On the axis triad in the graphics window click +Z to view from Z-direction.
This allows you to compare the size and shape of the flow inlet with that of the flow outlet without
distortion due to perspective.
Figure 4.5: Swelling of the Extrudate
Since the model involves a generalized Newtonian fluid, there are no viscoelastic effects. The swelling
(Figure 4.5: Swelling of the Extrudate (p. 21)) is only due to reorganization of the velocity profile at the
die exit. Fluid from high-speed region moves to low-speed region and pushes the free surface to the
exterior.
5. Create a 2D plot on the diagonal of the die.
a. Define the line of the plot with the points (0.0, 0.1, 0.1) and (0.1, 0.0, 0.1).
These values are in meters.
i. Select Line from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Line 1) and display the details view below the Outline
tab.
3D Extrusion
iii. Enter 0, 0.1, 0.1 for Point 1 and 0.1, 0, 0.1 for Point 2.
iv. Click Apply.
b. Create a plot.
i. Click the chart button .
ii. Click OK to accept the default name (Chart 1) and display the details view below the Outline
tab.
iii. In the General tab of the details view, select XY for the Type and enter 3D Extrusion for
Title.
iv. In the Data Series tab, for Series 1, select Line 1 from the Locations drop-down list (or by
clicking the button).
v. In the X Axis tab, select X from the Variable drop-down list.
vi. In the Y Axis tab, select VELOCITIES from the Variable drop-down list.
vii. Click Apply.
3D Extrusion
Figure 4.6: Velocity Magnitude Along a Diagonal of Die Exit Section
The shear-thinning introduced by the Cross law is not clearly visible in Figure 4.6: Velocity Magnitude
Along a Diagonal of Die Exit Section (p. 24) due to the large finite elements along the die wall. The
mesh should be refined in that zone.
6. Plot X-velocity close to center of the die.
a. Define the line of the plot with the points (0.08, 0.02, 0.00) and (0.08, 0.02, 0.50).
i. Select Line from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Line 2) and display the details view below the Outline
tab.
iii. Enter 0.08, 0.02, 0 for Point 1 and 0.08, 0.02, 0.5 for Point 2.
iv. Click Apply.
b. Create a plot.
i. Click the chart button .
ii. Click OK to accept the default name (Chart 2) and display the details view below the Outline
tab.
iii. In the General tab of the details view, select XY for the Type and disable Display Title.
iv. In the Data Series tab, select Line 2 from the Locations drop-down list for Series 1.
v. In the X Axis tab, select Z from the Variable drop-down list.
vi. In the Y Axis tab, select VELOCITIES X from the Variable drop-down list.
vii. Click Apply.
Figure 4.7: X-Velocities Along a Line Close to the Center of the Die
7. Plot Y-velocity close to the center of the die.
a. In the Y Axis tab of the details of Chart 2, select VELOCITIES Y from the Variable drop-down list.
b. Click Apply.
3D Extrusion
Figure 4.8: Y-Velocities Along a Line Close to the Center of the Die
8. Plot Z-velocity close to the center of the die.
a. In the Y Axis tab of the details view of Chart 2, select VELOCITIES Z from the Variable drop-down
list.
b. Click Apply.
Figure 4.9: Velocities Along a Line Close to the Center of the Die (p. 27) shows that the flow
slows down ( decreases) after the die exit. Meanwhile, particles travel from the center of
the extrudate toward the edge, creating the swelling of the extrudate. Figure 4.7: X-Velocities
Along a Line Close to the Center of the Die (p. 25) and Figure 4.8: Y-Velocities Along a Line
Close to the Center of the Die (p. 26) show that the peak values of and are located at
the very beginning of the extrudate, and vanish at the end of the free jet.
Summary
Figure 4.9: Velocities Along a Line Close to the Center of the Die
4.13. Summary
This tutorial introduced the concept of a 3D extrusion problem. You solved the problem using a specific
3D geometry for the die and made suitable assumptions about the physics of the problem. You analyzed
the factors affecting the extrudate shape. In Polydata you learned how to use the optimesh remeshing
method, which is recommended for 3D extrusion problems.

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Chapter 4: 3D Extrusion

In this tutorial you will learn how to:

Create a sub-task to define a 3D extrusion problem.

Set material properties and boundary conditions for a 3D extrusion problem.

Select a remeshing method.

4.3. Problem Description

Figure 4.1: Problem Description

boundary 1: flow inlet, volumetric flow rate = 10 cm3/s

boundary 2: zero velocity

boundary 3: symmetry plane

boundary 4: symmetry plane

boundary 5: free surface

boundary 6: flow exit

Figure 4.2: Boundary Sets for the Problem

1. Prepare a working folder for your simulation.

2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.

3. Enter the name of this tutorial into the search bar.

a. Click ANSYS Polyflow under Product.

b. Click 15.0 under Version.

5. Select this tutorial from the list.

6. Click Files to download the input and solution files.

The mesh file ext3d.msh can be found in the unzipped folder.

4.5. Step 1: Project and Mesh

3. Import the mesh file (ext3d.msh).

4. Double-click the Setup cell to start Polydata.

4.6. Step 2: Models

1. Create a task for the model.

Create a new task

a. Retain the following (default) options:

b. Click Accept the current setup.

The Create a sub-task menu item is highlighted.

2. Create a sub-task for the isothermal flow.

a. Select Generalized Newtonian isothermal flow problem.

A panel appears asking for the title of the problem.

b. Enter 3D die swell as the New value and click OK.

The Domain of the sub-task menu item is highlighted.

3. Define the domain where the sub-task applies.

Domain of the sub-task

The Material data menu item is highlighted.

4.7. Step 3: Material Data

1. Click Shear-rate dependence of viscosity.

2. Click Cross law.

= zero shear-rate viscosity = 85000

= natural time = 0.2

= Cross law index = 0.3

3. Specify the value .

Enter 85000 as the New value and click OK.

4. Specify the value for .

Enter 0.2 as the New value and click OK.

5. Specify the value for .

Enter 0.3 as the New value and click OK.

The Flow boundary conditions menu item is highlighted.

4.8. Step 4: Boundary Conditions

Flow boundary conditions

1. Set the conditions at the flow inlet (BOUNDARY_1).

c. Retain the default settings, Automatic and Volumetric flow rate.

d. Click Modify volumetric flow rate.

Enter 10 as the New Value and click OK.

e. Click Upper level menu.

3. Set the conditions at the first symmetry plane (BOUNDARY_3).

b. Click Plane of symmetry (fs=0, vn=0).

4. Set the conditions at the second symmetry plane (BOUNDARY_4).

b. Click Plane of symmetry (fs=0, vn=0).

5. Set the conditions at the free surface (BOUNDARY_5).