Optimization of coat-hanger melt distributors for the wire coating process

Abstract : The objective of the rheological design of extrusion dies in the wire coating process is to distribute the melt around the conductor uniformly. If the manifold is not designed properly, the velocity at the die exit may be not uniform. However, in this paper we present an optimal design approach, this approach involves coupling an optimization routine with mesh generators and three-dimensional finite element simulation software. The objective is to obtain optimal coat-hanger melt distributor geometry to ensuring a homogeneous exit velocities distribution without increase the pressure at the die entrance. For this purpose, we investigate the effect of the design variables in the objective and constraint function by using Taguchi method. In the second study we use the global response surface method and SQP algorithm in order to improve the exit velocities distribution by modify the manifold geometry using a simplified design model.