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In this work we present improved design guidelines to support the die designer activity, when searching for the flow channel geometry that allows the achievement of a balanced flow distribution, in complex profile extrusion dies. The proposed methodology relies on surrogate models, obtained through a detailed and extensive numerical study, carried out with the open source computational library OpenFOAM ® , in which an appropriate numerical solver for the problems under study was implemented. The main contribution of this work is to further enlarge the applicability of the simplified design methodology (Rajkumar A, Ferrás LL, Fernandes C, Carneiro OS, Becker M, Nóbrega JM.  Int. Polym. Proc.  2017, 32, 58–71.) previously proposed by this group for similar purposes, by considering the effect of processing parameters and material rheology. The sensitivity analyses performed showed that, among the studied parameters, the power-law exponent was the only one that affected the system behavior. Thus, the previous proposed surrogate models were modified to include the effect of this parameter. Verification studies performed for three geometries and different rheological and process parameters evidenced the effectiveness of the proposed simplified design methodology.

Guidelines for balancing the flow in extrusion dies: the influence of the material rheology