An optimization method with experimental validation for the design of extrusion wire coating dies for a range of different materials and operating conditions

Abstract The objective of this article is to determine a wire coating‐hanger melt distributor geometry to ensure a homogenous exit velocity distribution that will best accommodate a wide material range and multiple operating conditions (i.e., die wall temperature and flow rate change). The computational approach incorporates finite element (FE) analysis to evaluate the performance of a die design and includes a nonlinear constrained optimization algorithm based on the Kriging interpolation and sequential quadratic programming algorithm to update the die geometry. Two optimization problems are then solved, and the best solution is taken into account to manufacture the optimal distributor. The Taguchi method is used to investigate the effect of the operating conditions, i.e., melt and die wall temperature, flow rate and material change, on the velocity distribution for the optimal die. In the example chosen, the wire coating die geometry is optimized by taking into account the geometrical limitations imposed by the tool geometry. Finally, the FE analysis and optimization results are validated by comparison with the experimental data obtained with the optimal die. The purpose of the experiments described below is to investigate the effect of material change. POLYM. ENG. SCI., 2012. © 2012 Society of Plastics Engineers