Profile die design by pressure balancing and cross flow minimization

A strategy for the design of profile dies has been created based upon the assumption that there is no cross flow at all. This is referred to as the Avoid Cross Flow Strategy. In this approach the material flow through a series of cross sections (perpendicular to the machine direction) taken through the die is determined. Each cross section is then subdivided into a number of segments. The geometry of each cross section is then adjusted so that the mass flow rate through each segment of the cross section is in the same proportion as the area percentage of that segment of the cross section relative to the total cross sectional area of the final profile. Once the cross section geometries have been adjusted according to the above procedure they can then be connected to define the 3D flow channel. A software package for the simulation of fully developed isothermal flow through channels of arbitrary cross sections has been developed. Application of the simulation program along with the Avoid Cross Flow Strategy means that the material flow will be very nearly balanced and cross flows minimized. Fully 3D flow simulations were performed to verify that a well balanced flow condition is indeed achieved.