Optimal shape design of a polymer extrusion die by inverse formulation

The optimum design problem of a coat-hanger die is solved by the inverse formulation. The flow in the die is analyzed using three-dimensional model. The new model for the manifold geometry is developed for the inverse formulation. The inverse problem for the optimum die geometry is formed as the optimization problem whose objective function is the linear combination of the square sum of pressure gradient deviation at die exit and the penalty function relating to the measure of non-smoothness of solution. From the several iterative solutions of the optimization problem, the optimum solution can be obtained automatically while producing the uniform flow rate distribution at die exit.