Optimization of Polymer Processing: A Review (Part I-Extrusion)

Given the global economic and societal importance of the polymer industry, the continuous search for improvements in the various processing techniques is of practical primordial importance. This review evaluates the application of optimization methodologies to the main polymer processing operations. The most important characteristics related to the usage of optimization techniques, such as the nature of the objective function, the type of optimization algorithm, the modelling approach used to evaluate the solutions, and the parameters to optimize, are discussed. The aim is to identify the most important features of an optimization system for polymer processing problems and define the best procedure for each particular practical situation. For this purpose, the state of the art of the optimization methodologies usually employed is first presented, followed by an extensive review of the literature dealing with the major processing techniques, the discussion being completed by considering both the characteristics identified and the available optimization methodologies. This first part of the review focuses on extrusion, namely single and twin-screw extruders, extrusion dies, and calibrators. It is concluded that there is a set of methodologies that can be confidently applied in polymer processing with a very good performance and without the need of demanding computation requirements.

Flow Balancing in Extrusion Dies for Thermoplastic Profiles

A computer code, previously developed by the authors for the automatic die design, is used to optimise the flow distribution in a profile extrusion die using two alternative strategies: one based on length optimisation and the other on thickness optimisation. The numerical predictions are then compared with experimental data gathered during extrusion experiments. The numerical predictions and the experimental results agree within the experimental uncertainty thus showing the effectiveness of the computer code, the optimisation algorithm and the design strategies implemented. Generally speaking, measured and predicted values of pressure drop and flow rate are in good agreement (within 8 % and 6 %, respectively). It also is confirmed that optimisation based on thickness control leads to final profiles that are more prone to distortion.