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http://www.hitechcae.com/case-studies/fea/design-optimization-of-breaker-plate-in-extrusion-machines.php
Design Optimization of Breaker Plate in Extrusion Machines Case Study Highlights Client Profile: Leading Extrusion Machine Manufacturer, USA Objective: To optimize the breaker plate design for maximum number of holes of different sizes while maintaining the stress values within the permissible range. Challenges: Identify maximum number of holes for each = given hole size
Breaker plates are essentially required in extruders to cover filter screens, and provide uniform melting and mixing of the polymer before entering the die. The number of holes in breaker plates has a direct impact on the time required for the forming process. A leading extrusion machine manufacturer approached Hi-Tech to re-engineer the breaker plate, by increasing the number of holes of different sizes for a given design space. The customer also needed to analyze the optimized breaker plate design for stress distribution and subsequent deformation.
= Maintaining sufficient edge to edge gap
between the holes to avoid dimensional irregularity due to deformation Solution: For given sizes of holes, the parametric model was developed using ANSYS CAD tool to identify maximum number of holes that can be drilled on the breaker plate. A followed stress analysis was performed to evaluate the deformation values for the breaker plates of different sizes of holes. Software We Used : ANSYS Professional NLS 14.5
The Solution Hi-Tech’s engineering team developed optimized breaker plate design with maximized number of holes of different sizes. Providing three different hole configurations for a given break plate geometry, the optimized design was also evaluated for stress distribution and deformation. The edge to edge thickness between the successive holes was also crucial, to avoid excessive deformation due to stress generation. With consecutive iterations considering the different parameters, three optimized breaker plate designs were proposed possessing maximum number of holes as well as maintaining the stress and deformation values within the allowable limits.This solution can also be provided using Altair Hyperworks, Autodesk Simulation, NASTRAN, Abaqus, Pro-Mechanica, NX-CAE.
Benefits = Increased productivity from the extrusion machine
with optimized breaker plate = Reduction in time required for plastic forming = Alternative breaker plate configurations with
different hole sizes to suit specific applications = Decreased the time required to perform
prototyping tests
Author: Bhaumik Dave
About Hi-Tech
FEA Consultant
Hi-Tech CAE is a division of Hi-Tech Outsourcing Services, a pioneer engineering outsourcing company since 1992 based in India & USA. It provides expert Computer Aided Engineering - CAE consulting services for engineering / product design analysis by modeling & simulation. The primary services extended include Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), product design optimization and value engineering services to Automotive, Building / Construction, Process industry, Power Generation, Manufacturing & Heavy Engineering industries..
Phone: +1-408-338-8047 Email: info@hitechcae.com
Outsourcing Services Your Trusted Outsourcing Partner
Hi-Tech Outsourcing Services 547 Moreland Way Santa Clara, CA 95054
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