Rotating Die Profile Shaping for Viscoelastic Extrusion
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Solution Overview
Problem
Existing extrusion and pultrusion devices struggle to optimize the profile definition zone for materials that undergo plastic deformation and have elastic properties, leading to issues with high force resistance and potential damage during production.
Innovation Solution
A device with a rotating die and counter-bearing, featuring a first channel section for initial deformation and a second channel section for further shaping, controlled by a wake element and rotating die pattern to manage pressure and material elasticity, ensuring high-quality profile production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotating die is used in the second channel section to exert pressure on 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
Solution Approach 1:
The profile definition zone is divided into two distinct channel sections: a first channel section with static walls for initial deformation, and a second channel section with a rotating die for final shaping. This segmentation allows the material to undergo gradual deformation, reducing stress concentration and rupture risk while maintaining production efficiency and profile quality.
Solution Approach 2:
The first channel section performs preliminary deformation of the material into a master profile before the material enters the second channel section. This preliminary action prepares the material for the subsequent high-pressure rotating die operation, reducing the likelihood of rupture during the final shaping process.
2Productivity
If a rotating die is used immediately downstream a traditional extrusion device, then productivity is improved, but device complexity increases due to the combination of static and moving parts
Solution Approach 1:
The invention merges a traditional extrusion device with a rotating die system into a single integrated profile definition zone. The static first channel section and the moving second channel section with rotating die work together as one cohesive unit, achieving high productivity while managing device complexity through functional integration.
Solution Approach 2:
The profile definition zone serves multiple functions: it performs initial deformation in the first channel section, applies controlled pressure in the second channel section, and defines the final profile shape. This multi-functionality reduces the need for separate processing stages, improving productivity while consolidating device structure.
3Manufacturing precision
If the first channel section is optimized for minimum side leakage, then manufacturing precision is improved, but the load rate control becomes more difficult
Solution Approach 1:
The first channel section is specifically designed with optimized geometry and wall configurations to minimize side leakage locally. This localized optimization ensures accurate profile shaping without requiring complex overall load rate control mechanisms, maintaining ease of operation while achieving high manufacturing precision.
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
The solution allows for controlled pressure application, reducing the risk of material rupture and device damage while maintaining high production quality and speed, optimizing the transition from a master to final profile.
Implementation Method 1
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
Implementation Method 2
forming a profile product made from a viscoelastic material and/or plastically deformable material with elastic property
Implementation Method 3
materials made from a viscoelastic material and/or plastically deformable material with elastic property and/or viscoplastic material with elastic property
Data Source
AI summary
A method and an extrusion- or pultrusion device for forming a profile product made from a viscoelastic material and/or plastically deformable material with elastic property and/or viscoplastic material with elastic property in a production direction. The device comprises 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 (X) 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.