Rotating Die Profile Zone for Load-Controlled Extrusion Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing extrusion and pultrusion devices struggle to optimize the profile definition zone for materials that undergo plastic deformation, viscoelastic deformation, and viscoplastic deformation, leading to challenges in producing high-quality profile products at high speeds and maintaining device integrity.
Innovation Solution
The device incorporates a rotating die with a profile definition zone featuring a first channel section and a second channel section, optimized for controlling load rates and material deformation, allowing for the integration of multiple materials and controlling friction through inlet channels and friction materials, with the rotating die exerting pressure to form layered or embedded products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotating die is used in the second channel section to exert pressure onto the material surface, then manufacturing precision and production speed are improved, but the risk of material rupture and device damage increases due to high forces during operation
Solution Approach 1:
The profile definition zone is divided into two distinct channel sections: a first channel section with static walls for initial material shaping, and a second channel section with a rotating die for final profile formation. This segmentation allows each section to be optimized for its specific function, distributing the mechanical loads and reducing the risk of device damage while maintaining manufacturing precision.
Solution Approach 2:
The second channel section employs a rotating die that rotates about an axis extending across the production direction, transforming the static pressing mechanism into a dynamic one. This rotation distributes the high forces over time and across different contact points, reducing peak stresses on the device structure while maintaining the required manufacturing precision through controlled pressure application.
2Productivity
If the first channel section is optimized for minimum side leakage, then productivity increases, but the load rate control becomes insufficient for materials undergoing plastic deformation
Solution Approach 1:
Different channel sections are designed with different geometric characteristics optimized for their specific functions. The first channel section has dimensions and wall configurations optimized for minimizing side leakage and maintaining high productivity. The second channel section is designed with specific geometric features that provide appropriate load rate control for materials undergoing plastic deformation, ensuring both productivity and manufacturing precision are achieved in their respective zones.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of high-quality profile products with multiple layers or embedded materials, maintaining high production rates while reducing the risk of material rupture and device damage by optimizing pressure and friction control.
Implementation Method 1
materials that undergo plastic deformation have special features/properties that have to be taken into account
Implementation Method 2
materials that undergo plastic deformation and/or materials made from a viscoelastic material
Implementation Method 3
controlling friction through inlet channels and friction materials
Data Source
AI summary
A method and an extrusion or pultrusion device for forming a profile product made from a material in a production direction, said device comprising a rotating die, extending in a radial direction and a width direction, having two opposite first and second side walls and an outer circumferential surface extending in the width direction therebetween, wherein the rotating die comprises a first side portion in connection to the first side wall and a second side portion in connection to the second side wall and a mid-portion extending between the first and second side portions, and a profile definition zone having a longitudinal direction coinciding with the production direction, a height direction and a width direction being perpendicular to the height direction, comprising a through channel comprising a first channel section followed by a second channel section downstream the first channel section with reference to the production direction, wherein the rotating die is rotatable about an axis extending across the production direction and arranged to allow the outer circumferential surface to, while the rotating die rotates, exert a pressure onto a surface of the material when fed through the profile definition zone.