Polyflow Extrusion WS06 Inverse Extrusion

Chapter 6: Inverse Extrusion
6.1. Introduction
Inverse extrusion deals with the computation of the shape of a die that produces an extrudate of the
desired shape. This tutorial illustrates how to handle a complex inverse extrusion problem. In this tutorial,
slip conditions along the die walls are considered and evolution on the slip coefficient is enabled to
aid convergence.
In this tutorial you will learn how to:
Define an evolution problem.
Create a sub-task to define an inverse extrusion problem.
Set material properties and boundary conditions for a inverse extrusion problem.
Specify multiple local remeshing regions.
6.2. Prerequisites
This tutorial assumes that you are familiar with the menu structure in Polydata and Workbench and
that you have solved or read 2.5D Axisymmetric Extrusion (p. ?). Some steps in the set up procedure
will not be shown explicitly.
6.3. Problem Description

This problem deals with the flow of a Newtonian fluid through a three-dimensional die. Due to the
symmetry of the problem (the cross-section of the die is a polygon), the computational domain of the
fluid is defined for a quarter of the geometry. Two planes of symmetry are defined.
The melt enters the die as shown in Figure 6.1: Problem Description (p. 2) at a flow rate = 200 cm3/s
(a quarter of the actual flow rate) and the extrudate is obtained at the exit.
The incompressibility and momentum equations are solved over the computational domain. The domain
for the problem is divided into two sub-domains (as shown in Figure 6.1: Problem Description (p. 2))
so that specific remeshing algorithms can be applied in each sub-domain to accurately predict the die
profile. Subdomain 1 represents the fluid as it enters and is confined by the die. Subdomain 2 corresponds
to the extrudate that is in contact with the air (and can deform freely). The main aim of the calculation
is to compute the geometry of the die to obtain the desired extrudate.
Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 1
Inverse Extrusion
Figure 6.1: Problem Description
Figure 6.2: Boundary Set for the Problem
The boundary set for the problem are shown in Figure 6.2: Boundary Set for the Problem (p. 2), and
the conditions at the boundaries of the domains are given below
boundaries of the domains are:
boundary 1: flow inlet, volumetric flow rate = 200 cm3/s
2 of ANSYS, Inc. and its subsidiaries and affiliates.
Step 1: Project and Mesh
boundary 2: symmetry plane
boundary 3: symmetry plane
boundary 4: slip conditions along the wall
boundary 5: free surface
boundary 6: flow exit
6.4. Preparation
To prepare for running this tutorial:
1. Prepare a working folder for your simulation.
2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3. Enter the name of this tutorial into the search bar.
4. Narrow the results by using the filter on the left side of the page.
a. Click ANSYS Polyflow under Product.
b. Click 15.0 under Version.
5. Select this tutorial from the list.
6. Click Files to download the input and solution files.
7. Unzip the Inverse-Extrusion_R150.zip file you have downloaded to your working folder.
The mesh file invext.msh can be found in the unzipped folder.
8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.
6.5. Step 1: Project and Mesh

1. Create a Fluid Flow (Polyflow) analysis system by drag and drop in Workbench.
2. Save the ANSYS Workbench project using File Save, entering inverse-extrusion as the name
of the project.
3. Import the mesh file (invext.msh).
4. Double-click the Setup cell to start Polydata.
Inverse Extrusion
When Polydata starts, the Create a new task menu item is highlighted, and the geometry for the
problem is displayed in the Graphics Display window.
6.6. Step 2: Models

In this step, define a new task representing the inverse extrusion model. Then, define a sub-task for the iso-
thermal flow calculation.
1. Create a task for the model.
Create a new task
a. Select the following options:
F.E.M. task
Evolution problem(s)
Apply the evolution scheme on the slip coefficient along the outer wall of the die (boundary 4)
when you define the slip boundary conditions.
b. Click Accept the current setup.
The Create a sub-task menu item is highlighted.
2. Create a sub-task for the isothermal flow.
Create a sub-task
a. Click Generalized Newtonian isothermal flow problem.
A panel appears asking for the title of the problem.
b. Enter Inverse Extrusion as the New value and click OK.
The Domain of the sub-task menu item is highlighted.
3. Define the domain where the sub-task applies.
Step 3: Material Data
This problem involves a free surface, so the domain is divided into two sub-domains; one for the region
near the free surface (SUBDOMAIN_2) and the other for the rest of the domain (SUBDOMAIN_1). In this
problem, the sub-task applies to both sub-domains, which is the default condition.
Domain of the sub-task
Accept the default selection of both subdomains by clicking Upper level menu.
The Material data menu item is highlighted.
6.7. Step 3: Material Data

Polydata indicates which material properties are relevant for your sub-task by graying out the irrelevant
properties. In this case, viscosity, density, inertia terms, and gravity are available for specification. For this
model, define only the viscosity of the material.
Material Data
1. Click Shear-rate dependence of viscosity.
2. Click Power law.
The viscosity in this tutorial is given by the power law. For information on power law, see Power
Law (p. 24).
3. Specify the value of .
Modify fac
Enter 30 as the New value and click OK.
4. Retain the default value for .
Modify tnat
Click OK to retain the default value of 1.
5. Specify the value for .
Modify expo
Inverse Extrusion
Enter 0.75 as the New value and click OK.
6. Click Upper level menu three times to return to the Inverse Extrusion menu.
The Flow boundary conditions menu item is highlighted.
6.8. Step 4: Boundary Conditions

In this step, set the conditions at each of the boundaries of the domain. When a boundary set is selected, its
location is highlighted in red in the graphics window.
Flow boundary conditions
1. Set the conditions at the flow inlet (BOUNDARY_1).
a. Select Zero wall velocity (vn=vs=0) along BOUNDARY_1 and click Modify.
b. Click Inflow.
c. Click Modify volumetric flow rate.
Polydata prompts you for the volumetric flow rate.
d. Enter 200 as the New value and click OK.
e. Retain the default options of Automatic and Volumetric flow rate.
f. Click Upper level menu.
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow condition.
2. Set the conditions at the first symmetry plane (BOUNDARY_2).
In 2D axisymmetric problems, the axis of symmetry is automatically identified by Polydata, but for 3D
flows, you must manually identify a plane of symmetry.
The normal velocity ( ) and the tangential force ( ) are set to zero on a symmetry plane. A particle
cannot cross the plane ( = 0) due to the symmetry, so the particles flow at the same velocity on both
sides of the symmetry plane, leading to a zero tangential force.
Step 4: Boundary Conditions
b. Click Plane of symmetry (fs=0, vn=0).
3. Set the conditions at the second symmetry plane (BOUNDARY_3).
b. Click Plane of symmetry (fs=0, vn=0).
4. Set the conditions along the outer wall of the die (BOUNDARY_4).
b. Enable the evolution scheme on the slip coefficient.
For information on the evolution scheme, see Evolution Scheme (p. 24).
i. Click EVOL at the top of the Polydata menu to enable the evolution inputs for the slip coeffi-
cient.
ii. Click Slip conditions.
iii. Click F(v) = Generalized Naviers law.
For information on Naviers law, see Appendix (p. 24).
iv. Specify the value of .
Modify k
A panel appears asking you for the value of .
v. Retain the default value of 1 for k and click OK.
vi. Select the function f(S) = a*exp(b*S) + c + d*S.
You will retain the default values for a and b, and will modify the values for c and d.
vii. Click Modify the value of c.
Hint: Scroll down to see Modify the value of c.
A panel appears asking for the new value of c.
viii. Enter 0 as the New value and click OK.
ix. Click Modify the value of d.
A panel appears asking for the new value of d.
x. Enter 0 as the New value and click OK.
xi. Click EVOL at the top of the Polydata menu to disable the evolution inputs.
Inverse Extrusion
xii. Click Upper level menu.
xiii. Retain the default value of 1 for e ( ).
xiv. Click Upper level menu two times to return to the Flow boundary conditions menu.
5. Set the conditions at the free surface (BOUNDARY_5).
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid particles
go out of the domain through the free surface. This constraint is called the kinematic condition, =
0. This equation requires an initial condition (the starting line of the free surface). In this problem, the
starting line of the free surface is the intersection of boundary 4 and boundary 5 (see Figure 5.2: Boundary
Set for the Problem (p. ?)).
b. Click Free surface.
c. Click Boundary conditions on the moving surface.
d. Select No condition along BOUNDARY_4 (the boundary where the free surface starts) and click
Modify.
e. Select Position imposed.
f. Click Upper level menu to return to the Boundary conditions on the moving surface menu.
g. Click Upper level menu at the top of the menu.
h. Click Outlet (Inv. prediction) to define the outlet of the moving surface.
In inverse extrusion problems, you have to predict the appropriate die exit cross-section to obtain
a given extrudate cross-section. By defining the outlet of a free surface, inform Polyflow the desired
extrudate shape. Hence, you impose the outlet of the moving surface along the last section of the
free jet as the outlet of the free surface. This section will not be modified during the calculation.
i. Select BOUNDARY_6 as the outlet of the moving surface and click Confirm.
j. Click Upper level menu to return to the Flow boundary conditions menu.
6. Set the conditions at the flow exit (BOUNDARY_6).
It is assumed that a uniform velocity profile is reached at the exit. The melt is not subjected to any ex-
ternally applied stress at the exit, so the condition of zero normal and tangential forces is selected.
b. Click Normal and tangential forces imposed (fn, fs).
c. Accept the default value of 0 for the normal force, , by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force, , by clicking Upper level menu.
Step 5: Remeshing
7. Click Upper level menu at the top of the Flow boundary conditions menu.
The Global remeshing menu item is highlighted.
6.9. Step 5: Remeshing

The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface, since a part of the mesh is deformed. For information
on remeshing technique, see Appendix (p. 24).
Global remeshing
1. Specify the region where the remeshing is to be performed (SUBDOMAIN_2).
1st local remeshing
a. Select SUBDOMAIN_1 and click Remove.
SUBDOMAIN_1 is moved from the top list to the bottom list, indicating that only SUBDOMAIN_2
will be remeshed.
b. Click Upper level menu.
2. Define the parameters for the fist local remeshing method.
For 3D extrusion problems where large deformations of the extrudate are expected, the optimesh
remeshing technique is recommended. For information on optimesh remeshing technique see
Appendix (p. 24).
Optimesh-3D (extrusion only)
a. Specify the initial plane for the optimesh remeshing technique, by selecting Intersection with
SUBDOMAIN_1 and clicking Confirm.
b. Specify the final plane for the remeshing technique, by selecting Intersection with BOUNDARY_6
and clicking Confirm.
Polydata asks you whether you want to use the surface kinematic condition.
c. Click Yes to use the kinematic condition.
Inverse Extrusion
The line kinematic condition is recommended for extrusion problems, and must be used in combin-
ation with the optimesh remeshing technique.
d. Click Accept the current setup in the Element distortion check menu.
In complex extrusion simulations, the finite element mesh can undergo great deformations. The
Element distortion check menu deals with the detection of all possible distortions of the elements.
Accept default options.
3. Activate the inverse prediction.
Inverse prediction management
a. Click Enable the inverse prediction.
The technique of inverse prediction is selected to calculate the profile for the constant section
region of the die.
b. Click Upper level menu.
4. Specify a second region for remeshing (SUBDOMAIN_1).
a. Click Creation of a local remeshing.
b. Select SUBDOMAIN_1 and click Add.
c. Click Upper level menu.
d. Click Constant section for prediction.
e. Click Accept the current setup.
5. Click Upper level menu two times.
The F.E.M. Task 1 menu is displayed.
6.10. Step 6: Numerical Parameters

All information relevant to iterative schemes (for the F.E.M. task calculations) can be modified in the Numer-
ical parameters menu.
Numerical parameters
1. Specify the evolution parameters.
Modify the evolution parameters
a. Specify the final value of .
Modify the upper limit of S
Step 7: Outputs
Enter 20 for the New value and click OK.
b. Specify the initial value of .
Modify the initial value of delta-S
c. Specify the minimum value of .
Modify the min value of delta-S
Enter 0.1 for the New value and click OK.
d. Specify the maximum value of .
Modify the max value of delta-S
e. Specify the maximum number of successful steps.
Modify the max number of successful steps
2. Click Upper level menu three times to return to the top-level Polydata menu.
6.11. Step 7: Outputs

After Polyflow calculates a solution, it can save the results in several different formats. Choose the one that
is appropriate for your postprocessor. In this case, save the outputs in IGES format, as well as the default
format for CFD-Post.
Outputs
1. Retain the default output (CFD-Post) and click Enable Iges file output.
The default CFD-Post output is used for postprocessing with CFD-Post. The IGES output contains the
modified geometry of the extrudate (after remeshing) calculated at every step of the evolution procedure.
For information on IGES output, see Appendix (p. 24).
Polydata asks you to confirm the current system units and fields that are to be saved to the results file
for postprocessing.
2. Specify the system of units for the simulation.
a. Click Modify system of units.
b. Select Set to metric_cm/g/s/A+Celsius.
c. Click Upper level menu three times.
Inverse Extrusion
The top-level Polydata menu is displayed.
6.12. Step 8: Save the Data and Exit Polydata

After defining your model in Polydata, you need to save the data file. In the next step, you will have to read
this data file into Polyflow and calculate a solution.
Save and exit
1. Click Accept.
This confirms that the default Current field(s) are correct.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
6.13. Step 9: Solution

Run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
A cfx.res file (corresponding to the eight evolution steps of the flow case) will be created.
2. Check for convergence in the listing file.
a. Right-click the Solution cell and select Listing Viewer....
Workbench opens the View listing file panel, which displays the listing file.
b. It is a common practice to confirm that the solution proceeded as expected by looking for the
following printed at the bottom of the listing file:
The computation succeeded.
6.14. Step 10: Postprocessing

Use CFD-Post to view the results of the Polyflow simulation.
1. Double-click the Results tab in the Workbench analysis and read the results files saved by Polyflow.
CFD-Post reads the solution fields that were saved to the results file.
2. Display the velocity distribution on the boundaries.
a. Deselect Wireframe in the Outline tree tab, under User Locations and Plots.
Step 10: Postprocessing
b. Click the Insert menu and select Contour or click the button.
c. Click OK to accept the default name (Contour 1) and open the details view below the Outline
tab.
d. Perform the following steps In the Geometry tab of the details view.
i. Click the button next to Locations.
ii. Select all topological entities under PFL in the Location Selector dialog box (use Shift for
multiple selection) and click OK.
iii. Select VELOCITIES from the Variable drop-down list (or by clicking ).
iv. Click Apply.
You can see in Figure 6.3: Contours of Velocity Magnitude (p. 14) that the velocity is zero along the die
wall, as expected, and there is a fully developed profile at the inlet of the die. At the die outlet, the velocity
profile changes to become constant throughout the extrudate cross-section. The transition between
these two states can be seen at the beginning of extrudate section.
Inverse Extrusion
Figure 6.3: Contours of Velocity Magnitude
3. Display contours of velocity in cross-sections.
a. Deselect the contours previously defined.
In the Outline tree tab, under User Locations and Plots deselect Contour 1.
b. Create the cross-section planes, at Z = 0, 3, 7 and 20 cm.
i. Select Plane from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Plane 1) and display the details view below the Outline
tab.
Inverse Extrusion
iii. In the Geometry tab of the details view, select XY Plane from the Method drop-down list.
iv. Enter 0 for Z.
v. Click Apply.
vi. Repeat steps 3.b.i.v. to create the other planes at Z = 0.03, 0.07, and 0.1999 m.
vii. In the Outline tree tab, under User Locations and Plots, deselect Plane 1, Plane 2, Plane 3,
and Plane 4.
c. Click the Insert menu and select Contour or click the button.
d. Click OK to accept the default name (Contour 2) and open the details view below the Outline
tree tab.
e. In the Outline tree tab under User Locations and Plots, select Wireframe.
f. Perform the following steps in the details view of Contour 2.
i. In the Geometry tab, click the button next to Locations.
Inverse Extrusion
ii. Select all planes under User Locations and Plots (use Shift for multiple selection).
iii. Click OK.
iv. Select VELOCITIES from the Variable drop-down list (or click ).
v. In the Render tab, disable Lighting.
vi. Click Apply.
The velocity profiles planes are located at the flow inlet, the flow outlet, and planes just before and after
the die exit as shown in Figure 6.4: Velocity Profile Planes (p. 19).
Compare the velocity profile within the die to the velocity profile just after the die exit at the end of the
computational domain.
The flow is fully developed in the die.
The velocity profile is flat in the extrudate, far away from the die exit. All particles in the cross-section
plane are at the same velocity.
Just after the die exit, there is a transitional zone where the velocity profile is reorganized.
The velocity profile on the plane = 7 cm is not fully developed, but it is not flat either.
The velocity rearrangement is the source of the deformation of the extrudate.
Figure 6.4: Velocity Profile Planes
4. Compare the cross-section shape of the extrudate with die.
a. Simplify the display.
In the Outline tree tab, under User Locations and Plots, deselect Contour 2 and Wireframe.
b. Display the die shape using a polyline.
i. Select Polyline from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Polyline 1) and display the details view below the Outline
tab.
Inverse Extrusion
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method
drop-down list.
iv. Click next to Boundary List and select SUBDOMAIN_1_BOUNDARY_4. Click OK to close
the Location Selector dialog box.
v. Select SUBDOMAIN_1_BOUNDARY_1 from the Intersect With drop-down list.
vi. In the Color tab, click next to Color and select dark blue.
vii. Click Apply.
c. Display the extrudate shape using a polyline.
i. Select Polyline from the Location drop-down menu ( ).
ii. Click OK to accept the default name (Polyline 2) and display the details view below the Outline
tab.
iii. In the Geometry tab of the details view, select Boundary Intersection from the Method
drop-down list.
iv. Select SUBDOMAIN_2_BOUNDARY_5 from the Boundary List drop-down list.
v. Select SUBDOMAIN_2_BOUNDARY_6 from the Intersect With drop-down list.
vi. Click Apply.
d. Right-click in the graphic window and select View From +Z under Predefined Camera.
5. Restore the symmetry.
a. Click the Insert menu and select Instance Transform, or click the button.
b. Click OK to accept the default name (Instance Transform 1) and display the details view below
the Outline tab.
Inverse Extrusion
c. Perform the following steps in the Definition tab of the details view of Instance Transform 1:
i. Disable Instancing Info From Domain.
ii. Enter 4 for Number of Graphical Instances.
iii. Ensure Apply Rotation is selected.
iv. Select Principal Axis from the Method drop-down list.
v. Select Z from the Axis drop-down list.
vi. Enable Full Circle under Instance Definition.
vii. Click Apply.
d. In the Outline tree tab, under User Locations and Plots, right-click Polyline 1 and click Edit (or
double-click Polyline 1).
e. In the View tab of the details view, scroll down and enable Apply Instancing Transform.
f. Select Instance Transform 1 from the Transform drop-down list.
g. Click Apply.
h. In the Outline tree tab, under User Locations and Plots, right-click Polyline 2 and click Edit (or
double-click Polyline 2).
i. Repeat steps 5..eg.
You can use the central-mouse button to zoom in and out. This allows you to compare the size and
shape of the flow inlet with that of the flow outlet without distortion due to perspective.
You can also click the fit view button ( ) to properly center the image.
Figure 6.5: Swelling of the Extrudate
The deformation of the extrudate is the result of the rearrangement taking place at the die exit. Particle
coming from high-speed regions in the die must slow down, while particles coming from low-speed re-
gions must accelerate. You can change the speed by enlarging the flowing section. A tube of fluid at
high speed in the die will enlarge its cross-section in the extrudate to decrease its average velocity. A
tube of fluid at low speed in the die will reduce its cross-section in the extrudate in order to increase
average speed. In Figure 6.5: Swelling of the Extrudate (p. 23), you can see that the die design tool
compensated for these effects. The central part of the cross-section where the fluid easily flowed in the
original die has been reduced by the die design tool, while the extremities of the branches were enlarged
because the flow was much slower in the original die. Since the combined effects of the cross-sectional
enlargements and reductions are very difficult to guess, the numerical simulation is necessary to help
the die designer reduce the number of trial-and-error iterations.
Inverse Extrusion
6.15. Summary
This tutorial introduced the concept of an inverse extrusion problem. You solved the problem assuming
suitable conditions for the physics of the problem and Polyflow predicted the shape of the die. You
used multiple domain calculations with remeshing methods most suited to 3D inverse extrusion problems.
The non-linear problem was solved using an evolution technique to aid convergence.
6.16. Appendix
The appendix contains the following sections:
6.16.1. Power Law
6.16.2. Evolution Scheme
6.16.3. Remeshing Technique
6.16.4. Optimesh Remeshing Technique
6.16.5. IGES Output
6.16.1. Power Law

The power law exhibits shear thinning (reduction in the viscosity with an increase in shear rate) that is
a characteristic of many polymers. The viscosity in this tutorial is given by the power law:
(6.1)
where:
= consistency factor
= power-law index
= natural time
is included in the equation to make the units consistent.
6.16.2. Evolution Scheme

The kinematic equation introduces non-linear terms in the problem that might lead to convergence
difficulties. An evolution scheme is available in Polyflow to solve such highly non-linear problems. Start
the calculation with a reduced value of the parameter(s) causing the non-linearity. Starting from the
first solution, Polyflow increments the parameter(s) causing the non-linearity and computes a second
solution. Starting from this new solution, Polyflow increments the parameter(s) again and computes a
third solution. Following this procedure, Polyflow increases the value of each parameter up to its
nominal value. In Polyflow , this procedure is fully automated; the increments are automatically adapted
according to the results of previous calculations. Polyflow uses an evolution variable that is incremented
during the evolution scheme. S starts at an initial value of and is increased to a final value of . Each
parameter l that you want to evolve is defined as = .
Naviers Law: The generalized Naviers law is given by:

(6.2)
where:
= tangential velocity of the fluid
Appendix
= tangential velocity of the wall
= material parameters
= material parameters
= 0 (assumed zero, by default
6.16.3. Remeshing Technique

Remeshing for the inverse extrusion problems is carried out in two stages. This model involves a free
surface of unknown position. A portion of the mesh will be affected by the relocation of this boundary.
Hence a remeshing technique that is suitable for 3D extrusion problems is applied to this part of the
mesh. The free surface is entirely contained within subdomain 2, and hence only subdomain 2 will be
affected by the relocation of the free surface.
This technique modifies the location of the section where the boundary conditions on the kinematic
condition apply (the die-lip region). Apply local remeshing technique to the region between the entry
section and the die-lip area (subdomain 1). In this tutorial, you define a "constant section" on this sub-
domain. This means that the die cross-section is constant from the die entry to the die exit (a parallel
die). Using this two-stage remeshing technique, Polyflow calculates the die profile that produces an
extrudate of the desired shape. More complex deformations of the die are available via the definition
of different local remeshings within the die.
6.16.4. Optimesh Remeshing Technique

The optimesh remeshing technique requires the direction of extrusion to be parallel to the , , or
axis, and all slices into which the remeshing domain is cut must be perpendicular to the extrusion axis.
The domain to be remeshed is cut into a series of 2D slices (planes) in a direction perpendicular to the
direction of extrusion, and each plane will be remeshed independently. For this process, Polyflow requires
the selection of the initial plane and the final plane. In this problem, the initial plane is the intersection
of subdomain 2 with subdomain 1, and the final plane is the intersection of subdomain 2 with the flow
exit (boundary 6).
6.16.5. IGES Output

An IGES output allows you to import the final geometry into a CAD program. This is useful when you
are designing a die because you want to be able to manufacture the die predicted by the calculation.
In the present case, you can compare the final shape of the predicted extrudate in an IGES format with
the desired shape.

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Chapter 6: Inverse Extrusion

In this tutorial you will learn how to:

Define an evolution problem.

Create a sub-task to define an inverse extrusion problem.

Specify multiple local remeshing regions.

6.3. Problem Description

Figure 6.1: Problem Description

Figure 6.2: Boundary Set for the Problem

boundaries of the domains are:

boundary 1: flow inlet, volumetric flow rate = 200 cm3/s

boundary 2: symmetry plane

boundary 3: symmetry plane

boundary 4: slip conditions along the wall

boundary 5: free surface

boundary 6: flow exit

1. Prepare a working folder for your simulation.

2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.

3. Enter the name of this tutorial into the search bar.

a. Click ANSYS Polyflow under Product.

b. Click 15.0 under Version.

5. Select this tutorial from the list.

6. Click Files to download the input and solution files.

The mesh file invext.msh can be found in the unzipped folder.

6.5. Step 1: Project and Mesh

3. Import the mesh file (invext.msh).

4. Double-click the Setup cell to start Polydata.

6.6. Step 2: Models

1. Create a task for the model.

Create a new task

a. Select the following options:

b. Click Accept the current setup.

The Create a sub-task menu item is highlighted.

2. Create a sub-task for the isothermal flow.

a. Click Generalized Newtonian isothermal flow problem.

A panel appears asking for the title of the problem.

b. Enter Inverse Extrusion as the New value and click OK.

The Domain of the sub-task menu item is highlighted.

3. Define the domain where the sub-task applies.

Domain of the sub-task

The Material data menu item is highlighted.

6.7. Step 3: Material Data

1. Click Shear-rate dependence of viscosity.

2. Click Power law.

3. Specify the value of .

Enter 30 as the New value and click OK.

4. Retain the default value for .

Click OK to retain the default value of 1.

5. Specify the value for .

Enter 0.75 as the New value and click OK.

The Flow boundary conditions menu item is highlighted.

6.8. Step 4: Boundary Conditions

Flow boundary conditions

1. Set the conditions at the flow inlet (BOUNDARY_1).

c. Click Modify volumetric flow rate.

Polydata prompts you for the volumetric flow rate.

d. Enter 200 as the New value and click OK.

e. Retain the default options of Automatic and Volumetric flow rate.

f. Click Upper level menu.

2. Set the conditions at the first symmetry plane (BOUNDARY_2).

b. Click Plane of symmetry (fs=0, vn=0).

3. Set the conditions at the second symmetry plane (BOUNDARY_3).

b. Click Plane of symmetry (fs=0, vn=0).

b. Enable the evolution scheme on the slip coefficient.

ii. Click Slip conditions.

vi. Select the function f(S) = aexp(bS) + c + d*S.