b'Engineer Innovation | Plant & Processprocess. The responsible design engineer can carry out and evaluate the simulation independently.While in 2008 we needed several days for the calculation, the flow analysis for our extrusion dies are already completed after a few hours and we then calculate models with up to 15 million cells, explains Bernd Trapp, design engineer for extrusion tools.Figure 4a: Single strand toolFigure 4b: Multi strand tool Each extrusion tool is unique, and is put into operation and adapted directly on the machine after development. For each project, a comparison is made between the simulation and the flow-part during commissioning at the extrusion line, so that findings are continuously incorporated into the simulation process. Figure 6 shows the first flow part sample between the extrusion tool and the calibration unit. The red areas in the top left image were identified and optimized with the help of the simulation. The bottom image shows the optimized Figure 5: Optimized melt distribution in the right image (red areas). configuration, which is appropriate to be passed through the calibration unit.temperature limits in the complex tool, which is impossible to be estimatedExtension of the application areas since without simulation. In particular, through2008the complete embedding of SimcenterThe application areas of Simcenter FLOEFD in PTC Creo, in combination withFLOEFD are constantly extended. Initially, the automatic mesh generation, more andthe flow behavior in the extrusion dies faster optimization runs were madewas optimized (Figure 7). In this case, the possible. flow velocity, pressure, viscosity, shear rate, temperature, shear stress, and Extremely shortened developmentpressure distribution in the die were cycles with Simcenter FLOEFD optimized.The extrusion tool development cycles were shortened dramatically and the useThen the thermal design of the calibration of Simcenter FLOEFD made it possible totools was carried out with special integrate the computational fluidconsideration of the material properties. dynamics (CFD) simulation into the design(Figure 7 a, b). Followed by cooling Figure 6: Simulation and flow-part samples which were taken during the commissioning20'