Numerical Simulation of the Flat Die for Shape Optimization in the Single-screw Extrusion Process

In this study, we chose a flat die to optimize a general die geometry. The optimization was aimed at obtaining a uniform velocity distribution across the exit of the die. For the optimization, the input and output design parameters were randomly computed, and response surfaces were generated to obtain statistical data for the minimum and maximum sensitivities computed during optimization. Subsequently, object functions with constraints were numerically computed to obtain the minimum errors in the velocity difference (i.e., variable "Outp" in this study). Finally, we obtained the candidate optimized dataset. Note that the current numerical computations were simultaneously conducted for an entire extruder, i.e., screw plus die. The numerical outlet velocity distributions in the modified die geometry tended to be much more uniform than the conventional distributions in the current optimization processes for this specific flat die.