Polymer-Scintillator Extrusion Simulation, Die and Calibrator Design
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DNS CFD-Simulation, Navier-Stokes Equations, and Turbulence

Grand Challenge and Opportunity  ►  Beyond Preliminary CFD Simulation
 Beyond Die Design ► After-Die Stresses and Deformations
 Calibrator Design-Cooling Analysis ►Papers/Presentations
.......It is important to repeat again, that computational simulation and empirical extrusion engineering have their exclusive strengths and weaknesses and can not replace each-other, but if properly integrated, will strongly complement each-other, resulting in a synergistic result which is much greater than the simple sum of the two constituents ...more [Click for PDF file of this document formatted for printing]

Kostic, M. and L. G. Reifschneider, "Extrusion Die Design*" Encyclopedia of Chemical Processing (S. Lee, Editor); (c) 2005 by Dekker, ISBN: 0-8247-5563-4 (Hardcover 5 Volume Set, 3640 pages); (c) 2006 by Taylor & Francis, ISBN: 0-8247-5499-9 (electronic, Abstract) ...  More Publications ...

Collaborative Project:
NIU's Department of Mechanical Engineering, [ANTEC-PPT] [Fluent-PPT1*PPT2]].
NICADD - Northern Illinois Center for Accelerator and Detector Development (letter), and
Fermi National Accelerator Laboratory

Plastic scintillators are commonly used as particle detection devices in nuclear and high-energy physics experiments. At about $40 per kilogram cost of cast plastic scintillator, a very large-scale detector will not be affordable. However, using extruded plastic scintillators the cost is estimated at about $10/kg, and with further developments, the cost can be driven down, possibly to $5/kg. Several types of rectangular, triangular, and hexagonal extrudate profiles are used as plastic scintillators. These profiles have circular holes of 1.1 mm diameter to accommodate wavelength-shifting fiber-optic cables.

In a collaborative project involving Fermi National Accelerator Laboratory (FNAL), the Northern Illinois Center for Accelerator and Detector Development (NICADD), and the Department of Mechanical Engineering at Northern Illinois University (NIU), a CFD simulation of the extrusion die flow is being utilized to develop more effective die designs. The shape of the extrudate profiles being produced with a previous, old die did not produce the required sharp corners, nor was the center hole circular.  The ultimate objective of this work is to achieve required precision and quality of different, hollow profiles. In addition to CFD simulation, initial experiments at FNAL with the existing, old die are used to provide critical data, not accounted for by the simulation, for more accurate, new die design and extrusion process control. It is evident from collaborative work that the limitations and benefits of CFD simulation and experimentation cannot replace each-other, but they complement each other and both are necessary for optimal extrusion die design.

Professor Kostic's Extrusion Team:

Preliminary Reports and Documents:
ANTEC * Sabbatical'03 Report + * 12/09/03 + * Summer03Report * 3/6/03 Report * First Report * * P#1 &#2 (a photo from Fermi Lab visit in May '02) *Plan for Systematic Extrusion Experimental Research.html

Inverse Extrusion Simulation with FLUENT's PolyFLOW^®:
Extrusion and Coextrusion Simulation with PolyFLOW [Polymer Processing]

I like to repeat a phrase stated by Dr. Subbiah, Vice President of FLUENT at the 2002 UGM Opening Session: “With unprecedented advances in computational software and hardware, it is now possible for more people to get bad results faster and cheaper than ever before.” The message behind this quote is that many software are becoming more and more sophisticated, with more and more features and user friendlier, but we have to be very careful about how to use it and how to interpret and justify simulation outcomes. Profound understanding of physical phenomena and software features and constrains are very critical in properly setting-up simulations and outcomes justifications. Tendency of use of CFD simulation software by fluid/thermal non-experts is risky at best and may be costly. That why educational activities and expertise are very important and useful for industry and society as a whole.

One quarter of an extrudate velocity profile: rectangle with a center hole (inverse simulation and die design)

Links: www.berstorffcorp.com (*) SPE * EDI

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