ANSYS Polyflow

ANSYS Polyflow provides advanced fluid dynamics technology for companies in the polymer, glass, metals and cement processing industries. R&D teams use this technology extensively to design and optimize processes such as extrusion, thermoforming, blow molding, glass forming, fiber drawing and concrete shaping. For more than 25 years, design engineers have used Polyflow to minimize physical prototyping when manufacturing extrusion dies or to reduce thickness variation to improve the quality of thermoformed or blown products.

ANSYS Polyflow accelerates design while shrinking energy and raw material demands, making the manufacturing process cost effective and environmentally sustainable.

 

Because of a unique inverse die design capability, you can cut dies much faster than by using traditional build-and-test methods. This translates into substantial cost reduction and time savings. Your team can improve the quality of blown and thermoformed products by running trial-and-error processes with ANSYS Polyflow, rather than testing changes on the production line. Glass forming and float glass engineering simulations help designers to more quickly produce higher-quality tableware, glass containers and flat glass.

ANSYS Polyflow allows you to predict material distribution when using blow molding, such as with this 5 gallon blow-molded water cooler bottle.

 

Developing Better Packaging

Packaging is important to protect products from damage — but it is also a sustainability issue as well as an additional cost to raw materials suppliers. Deploying virtual prototyping using Polyflow enables you to model the manufacturing process. By coupling this solution with ANSYS explicit dynamics software and ANSYS Mechanical, your R&D team can evaluate and test a design’s behavior and durability. You can take corrective action at the design or manufacturing phase, or both, to quickly and cost effectively design lighter packaging with better performance.

 

Development teams can study the behavior of plastics and other materials, such as this example of injection stretch blow modeling using shell elements. Thickness distribution is shown.

 

By combining ANSYS Polyflow with our structural analysis tools, you can perform virtual prototyping of packaging: from CAD to blow molding to drop-test analysis.

 

Increasing Extrusion Line Efficiency

To meet tight tolerances that the market requires, some companies resort to trial-and-error methods for (co-)extruded plastic and rubber profiles. This approach is time intensive and costly, and it can negatively impact the environment. Using engineering simulation, including our unique inverse die design capability, you can gain a significant reduction in trial-and-error iterations for your extrusion lines. Some companies that apply our solutions have decreased the number of iterations from seven to two. Insight gleaned from visualizing the polymer flowing throughout the die allows you to quickly troubleshoot unexpected problems.

 

Polyflow’s mesh superposition technique allows you to take into account complex thermal and mechanical interactions for single- and twin-screw extruders.

 

Our tools assist in optimal thermoforming of an automotive dashboard design. Areas shown in blue are less thick, demonstrating a possible design weakness.