EuroWire November 2016

News Technology

Tool maker brings flow simulation analysis technology to crosshead

B&H Tool Company, of California, USA, a designer and manufacturer of high quality, custom plastic extrusion tooling, has added Computational Fluid Dynamics (CFD) analysis to its portfolio of approaches for optimising and designing annular dies for plastic extrusion. The flow simulation analysis software is completely integrated with its computer-aided design and manufacturing software to ensure high-quality tooling. “Management’s strategy is to bring the same approach to annular dies such as crosshead, in-line and co-extrusion dies, for single layer and co-extrusion applications. We want to bring the same technology that worked in film and sheet dies to annular die design,”said Peter Neville, B&H’s managing partner. With CFD, B&H’s team of experts design and manufacture annular dies that deliver uniform polymer flow to the exit of the die. The process starts with two required inputs: polymer rheology and a target output rate. With those inputs, designers can go to work to design a head assembly customised around a customer’s application. If a customer has multiple applications, B&H’s engineering team can help them determine where they want their target output rate to be. Analysing their output rates (as a function of pounds per hour) has been a big step forward for companies, Mr Neville reports. In many instances, across all industries, companies have not been looking at their tooling as an area of improvement. With the multitude of challenges faced in the manufacturing sector of both the USA and global economies, manufacturers have often been trying to use a ‘one-size-fits-all’ approach to their tooling capacity. CFD helps companies look at their tooling from a different perspective and help them straighten out their tooling. Often companies have developed ‘bandaids’ to compensate for uneven flow in their tooling. With CFD, B&H’s designers are able to simulate (before any metal is cut) polymer flow at a target out rate. With optimised tooling (as a function of pressure, velocity and shear), manufacturers can then focus on dialling in on the dimensions and quality of their products. Companies report faster start-ups and can operate with less-skilled operators because they are not ‘fighting’ the tooling as much. With operations in lesser developed countries or competitive industries, these can be significant issues. CFD is used for all types of annular dies – adjustable centre, fixed centre, co-extrusion, in-line and in-line spiderless dies. The approach is the same, as the goal is to deliver even flow to the exit of the die. Once the software inputs have been finalised and the tooling has been optimised using CFD, B&H’s team reviews the final design with the customer and goes over the simulation. Once the customer has signed off on the final design, then the job is ready to be sent to production. Since they have been involved in the process, the customer is able to integrate the tooling more efficiently once it lands on their receiving docks. CFD analysis is helpful in today’s more sophisticated plastic extrusion applications or high volume, low margin applications.

▲ ▲ Simulation analysis to ensure tooling is optimised for the application

Whether it is low output micro-bore tubing, insulated fine wire, multi-layer automotive tubing or multi-layer irrigation tubing, CFD ensures that the tooling is optimised for the application. For example, in irrigation tubing, post consumer polymers are used to bring down the cost of the tubing. Using CFD to make sure the rheology of ‘regrind’ is taken into consideration ensures that a major issue is addressed. In the case of low output applications, making sure the volume is optimised and the appropriate deflector is used is critical.

B&HTool Company – USA Website : www.bhtool.com

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November 2016