The Next Generation of Extrusion CAO System
SUNDYXTRUD
Features
Development concept
SUNDYXTRUD is an analytical system based on the general-purpose FEM high viscosity flow analysis program SUNDYBASIC, and features enhanced functions for the analysis of extrusion processes. SUNDYXTRUD has advantages, both as a research support tool and as a design support tool, and offers high cost performance. SUNDYXTRUD represents the evolution of conventional Computer Aided Engineering (CAE) into Computer Aided Optimization (CAO).
Research-supporting analytical functions
SUNDYXTRUD features a powerful 3D FEM analysis function that quantifies thermal flow phenomena in an extrusion forming process involving surface flow. This is done by accurately analyzing a 3D mathematical model consisting of a fluid conservation equation and a purely viscous constitutive equation.
Design-supporting analytical functions
SUNDYXTRUD has robust and high-performance functions for carrying out various analyses, such as 2D FEM analysis that assumes the developed thermal flow fields, simplified swell analysis and optimization analysis.
An optimization analysis function based on RSM (the Response Surface Method)
SUNDYXTRUD's optimization analysis based on the Response Surface Method lets you compute branching channel geometry that optimizes flow rate distribution inside a profile extrusion die, or die outlet section profile that achieves the required extrusion shape.
High-performance direct-method matrix solver
SUNDYXTRUD features a direct-method matrix solver that has excellent computational stability. The solver uses a renumber algorithm that optimizes the band width of the finite element discretization equation—which considerably improves computational efficiency.
General-purpose element library
Functions of SUNDYBASIC and SUNDYXTRUD
Analytical function SUNDY
BASIC		SUNDY
XTRUD
Thermal flow analysis Analysis of 2D/3D thermal flow in a die
Analysis of 2D sectional thermal flow in a die
Free surface flow analysis VOF method (injection molding)
ALE method (extrusion method)
Slip model (Navier's model)
Profile extrusion Single layer
Double layer
Optimization
Viscoelasticity
 :supported   : not supported   : Simplified
SUNDYXTRUD supports the use of all elements employed in finite element analysis. Users can select triangles or quadrilateral elements for 2D models, and tetrahedral, pentahedral or hexahedral elements for 3D models.
VOF method
SUNDYXTRUD uses the Volume of Fluid method to quantify the distribution of residence time for continuous bodies inside a die.
Simplified viscoelasticity analysis function
SUNDYXTRUD quantifies the effect of swell by evaluating viscoelastic normal stress under shear flow in a simplified manner.
Thermal flow analysis of the extrusion forming process
3D die thermal flow analysis
Pressure distributionResidence time distribution
Result of flow analysis in a spiral mandrel die
  • Prediction of thermal flow fields in complex geometry flow channels
  • Quantification of residence time distribution in a die, based on the VOF method
  • Input data: Flow channel/mold geometry, initial/boundary conditions of thermal flow, mold movement control settings, calculation control data, physical property model parameters
  • Output data: Thermal flow field
Profile extrusion analysis
Velocity distributionProfile extrusion shape
3D profile extrusion die swell simulation by generalized HF method
  • A generalized ALE (Arbitrary Lagrangian Eulerian) method is used for the integrated analysis of the 3D die region and extruded shape region.
  • Slip is described using Robin's boundary condition (Navier's slip model).
  • Multi-layer extrusion analysis
  • Input data: Channel geometry, boundary conditions of thermal flow field, calculation control data, physical property model parameters
  • Output data: Profile extrusion geometry data, thermal flow field
Simplified analysis
Predicted shape of extruded fluid from a die (amount of swell) and distribution of velocity in a developed flow field (simplified analysis)
Film formation process simulation with simplified consideration of viscoelastic stress
  • Prediction of thermal flow fields inside a section of the die, assuming a developed thermal flow field
  • Evaluation of viscoelastic normal stress, recoverable strain and swell using the prediction of developed thermal flow field
  • Input data: 2D channel section geometry, thermal flow boundary conditions, calculation control data, physical property model parameters
  • Output data: Developed thermal flow field in a 2D section of a flow channel, amount of swell
Optimization analysis
Branch flow channel initial geometry
Velocity distribution
Result of FEM flow analysis
of a slit die
Optimized branch flow channel geometry
Velocity distribution
Prediction result of optimum die geometry
for uniform average velocity
(RSM Optimization analysis)
  • Optimization of die geometry by the Response Surface Method (RSM)
  • Prediction of branching flow channel geometry that optimizes flow rate distribution inside the die
  • Prediction of die flow channel section geometry to achieve the required section geometry of extrusion
  • Input data: Flow channel initial geometry, extrusion product geometry, optimization condition (uniform average velocity condition or extrusion shape optimization condition), thermal flow field boundary conditions, calculation control data, physical property model parameters
  • Output data: Optimized geometry for distribution of flow rate in branching flow channels, optimized die outlet section geometry, thermal flow fields
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