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Title: Three dimensional simulation of rubber profile extrusion on the basis of in-line rheometry
Author: Rippl, A. P.
Awarding Body: University of Wales Swansea
Current Institution: Swansea University
Date of Award: 2005
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The work presented in this thesis is concerned with the accurate determination of material parameters and their use in three dimensional numerical simulation of the flow of rubber compounds through complex profile dies. In a first step, results from a study, based on classical rheometry conducted at the University of Wales Aberystwyth, are reviewed together with literature data. In conclusion of a comprehensive literature review, it is found that the existing literature on rubber compound material behaviour does not account for the separation of the different phenomena, i.e. in the most common case, wall slip effects are not separated from the shear behaviour and extensional viscosity is often neglected. The design of a novel in-line rheometer is presented, as classical laboratory rheo­metry is not considered adequate for taking into account the deformation history of the material as it proceeds through the extruder located upstream of the pro­file die. Extensive results gathered with this rheometer are used in an inverse material parameter determination scheme to obtain the parameters for the shear thinning, wall slip and extensional behaviour of the material. Subsequently, the new material parameters are used in the numerical study of a generic profile die especially designed for this purpose in order to display the various flow problems occurring in the real extrusion process. The design and instrumentation of trials on a profile production line at the in­dustrial collaborators site (Cooper Standard Products Ltd., Maesteg) for the aforementioned generic profile die are described. Experimental results for the flow distribution between the various limbs of the profile are compared with simulations. It is concluded, that the inclusion of extensional viscosity effects in the simulation is required, as a preliminary to the use of simulations in a computational optimisation scheme for profile dies.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available