CFD Analysis of Non-Isothermal Viscoelastic Flow of HDPE Melt Through an Extruder Die

The optimization of polymer extrusion processes is crucial for improving product quality and manufacturing efficiency in plastic industries. This study aims to investigate the viscoelastic flow behavior of high-density polyethylene (HDPE) through an extrusion die with an internal mandrel, focusing on the effects of die geometry and flow parameters. A two-dimensional (2D) numerical model is developed in COMSOL Multiphysics using the Oldroyd-B constitutive equation, solved using the Galerkin/least-square finite element method. The simulation results indicate that the Weissenberg number (Wi) and die geometry significantly influence the dimensionless drag coefficient (Cd) and viscoelastic stress distribution along the die wall. Furthermore, filleting sharp edges of the die wall surface effectively reduces stress oscillations, enhancing flow uniformity. These findings provide valuable insights for optimizing die design and improving polymer extrusion efficiency.