Polyflow Extrusion WS01 Axisymmetric

Chapter 1: 2.
5D Axisymmetric Extrusion
1.1. Introduction
This tutorial illustrates the setup and solution of a 2.5D axisymmetric extrusion problem. The problem
corresponds to a simplified 2D simulation of a swirling flow that occurs around the head of an extrusion
screw. The fluid is forced through the die and exits the +extruder after a short die land. The model in-
volves a free surface, the position of which is unknown.
In this tutorial you will learn how to:
Create a project in ANSYS Workbench.
Start Polydata from ANSYS Workbench.
Create a new task.
Create a sub-task.
Set material properties and boundary conditions for a 2.5D axisymmetric extrusion problem.
Select a remeshing method.
Specify output for CFD-Post.
1.2. Prerequisites
This tutorial assumes that you have little experience with Polyflow and its associated modules.
1.3. Problem Description

The problem to be considered is shown schematically in Figure 1.1: Problem Schematic (p. 2). The
fluid enters the domain at a flow rate of 10 cm3/s. The screw rotates at an angular velocity of 2 rad/s.
In the upper part of the domain, a free surface is used to model the extrudate going out of the extrusion
die. The position of the free surface is unknown. A portion of the mesh is affected by this unknown
boundary. A remeshing technique will be applied on this part of the mesh.
Release 15.0 - SAS IP, Inc. All rights reserved. - Contains proprietary and confidential information
of ANSYS, Inc. and its subsidiaries and affiliates. 1
2.5D Axisymmetric Extrusion
Figure 1.1: Problem Schematic
Since the problem involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain, as shown in Figure 1.2: Subdomains and
Boundary Sets for the Problem (p. 3)
2 of ANSYS, Inc. and its subsidiaries and affiliates.
Problem Description
Figure 1.2: Subdomains and Boundary Sets for the Problem
The boundary sets for the problem are also shown in Figure 1.2: Subdomains and Boundary Sets for the
Problem (p. 3), and the conditions at the boundaries of the domains are:
BS1: flow inlet
BS2: outer wall
BS3: free surface
BS4: flow exit
BS5: symmetry axis
BS6: rotating screw
1.4. Preparation
To prepare for running this tutorial:
1. Prepare a working folder for your simulation.
2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.
Note
If you do not have a User Name and Password, you can register by clicking Customer
Registration on the Log In page.
3. Enter the name of this tutorial into the search bar.
4. Narrow the results by using the filter on the left side of the page.
a. Click ANSYS Polyflow under Product.
b. Click 15.0 under Version.
5. Select this tutorial from the list.
6. Click Files to download the input and solution files.
7. Unzip the 2.5-Axi-Extrusion_R150.zip file you have downloaded to your working folder.
The mesh file ext2d.msh can be found in the unzipped folder.
8. Start Workbench from Start All Programs ANSYS 15.0 Workbench 15.0.
1.5. Step 1: Project and Mesh
Note
If you create the mesh in GAMBIT or a third-party CAD package, you need to convert it before
you read it into Polydata. In this tutorial, the mesh file has already been converted. So you
can read the mesh file directly into Polydata.
1. Create a Fluid Flow (Polyflow) analysis system by drag and drop in ANSYS Workbench.
Step 1: Project and Mesh
a. Rename the project name to Tutorial 1 by double-clicking and editing the text Fluid Flow
(Polyflow).
b. Save the ANSYS Workbench project using File Save.
c. Enter 2.5-axi-extrusion as the name of the ANSYS Workbench project.
This will create a 2.5-axi-extrusion.wbpj file and a folder named 2.5-axi-extru-

sion_files in the working directory. To reopen this project in a later ANSYS Workbench session,
use File Open.
2. Import the mesh file for the Polydata session.
Right-click the Mesh cell and click Import Mesh File.
a. Select ext2d.msh.
b. Click Open.
3. Double-click the Setup cell to start Polydata and read in the mesh. When Polydata starts, the Create a
new task menu item appears in bold text, and the geometry for the problem is displayed in the Graphics
Display window.
Note
At this point (when Create a new task appears in bold text) if you realize that you have
read the wrong mesh file, click STOP at the top of the Polydata menu and repeat the
process to access the correct mesh file.
Step 2: Models
1.6. Step 2: Models

In this step, first define a new task representing the 2.5D axisymmetric steady-state model. Then define a
sub-task for the isothermal flow calculation.
1. Create a task for the model.
Create a new task
a. Select the following options:
F.E.M. task
Steady-state problem(s)
2D 1/2 axisymmetric geometry
The Current setup (above the selected options) will be updated to reflect the selection. In any
problem solved using Polyflow, first an F.E.M. task is defined to calculate the flow field. If inform-
ation regarding the trajectories is necessary, specify a MIXING task after solving the problem
with the F.E.M. task specification and obtaining the results file. Then solve the problem once
again. 3D velocity components (u,v,w) are prescribed in a 2D cylindrical reference frame (r,z), so
2D 1/2 axisymmetric geometry has been chosen. A steady-state condition is assumed for this
problem.
b. Click Accept the current setup.
The Create a sub-task menu item appears in bold text.
Note
At this point (when Create a sub-task appears in bold text) if you realize that you
have made a mistake in the creation of the task and you need to return to that menu,
do the following:
i. Click Upper level menu to return to the top-level Polydata menu.
ii. Select Redefine global parameters of a task and make the necessary changes.
iii. Click Accept the current setup when you are satisfied with the corrected settings.
iv. Select F.E.M. Task 1.
2. Create a sub-task for the isothermal flow.
Create a sub-task
a. Select Generalized Newtonian isothermal flow problem.
A small panel appears asking for the title of the problem.
b. Enter die swell as the New value and click OK.
The Domain of the sub-task menu item appears in bold text.
Note
At this point (when Domain of the sub-task appears in bold text) if you realize that
you have made a mistake in the creation of the sub-task and you need to return to
that menu, do the following:
i. Click Upper level menu.
ii. Select Redefine global parameters of a sub-task and make the necessary changes.
iii. Click Upper level menu.
Step 3: Material Data
iv. Select die swell at the bottom of the existing menu.
The Domain of the sub-task menu item appears in bold text.
3. Define the domain where the sub-task applies.
Since this flow involves a free surface, the domain is divided into two subdomains: one for the region
near the free surface and the other for the rest of the domain. Here, the sub-task applies to both
subdomains (the default condition).
Domain of the sub-task
Accept the default selection of both subdomains by clicking Upper level menu.
The Material data menu item appears in bold text.
1.7. Step 3: Material Data

Polydata indicates the material properties that are relevant for your sub-task by dimming the irrelevant
properties. In this case, viscosity, density, inertia terms, and gravity are available for specification. For this
model, define only the viscosity of the material. Inertia effects are neglected and density is specified only
when inertia, gravity, heat convection, or natural convection is taken into account. Since gravitational effects
are not included in the model, the default value of zero is retained for gravity.
Material data
1. Click Shear-rate dependence of viscosity.
2. Click Cross law.
The viscosity is given by the Cross law:
where:
= zero-shear-rate viscosity = 85000
= natural time = 0.2
= Cross law index = 0.3
= shear rate
3. Specify the value for .
Modify fac
Enter 85000 as the New value and click OK.
4. Specify the value for .
Modify tnat
Step 4: Boundary Conditions
Enter 0.2 as the New value and click OK.
5. Specify the value form.
Modify expom
Enter 0.3 as the New value and click OK.
6. Check whether the values of the constants are correct, and repeat the previous steps if you need to
modify the constants again.
7. Click Upper level menu three times to leave the Material Data specification.
The Flow boundary conditions menu item appears in bold text.
1.8. Step 4: Boundary Conditions

In this step, set the conditions at each of the boundaries of the domain. When a boundary set is selected,
its location appears in bold text in red in the graphics window.
Flow boundary conditions
1. Set the conditions at the flow inlet (BS_1).
a. Select Zero wall velocity (vn=vs=0) along BS_1 and click Modify.
b. Click Inflow.
c. Click Modify volumetric flow rate.
Polydata prompts you for the volumetric flow rate.
d. Enter 10 as the New value and click OK.
e. Select Automatic and click Upper level menu.
When the Automatic option is selected, Polydata chooses the most appropriate method to compute
the inflow. In this case, Polydata will use a 1D finite-element technique to compute a 1D fully-developed
velocity profile, based on the specified material properties and flow rate. Moreover, the inflow
boundary condition requires that the computational domain be built in such a way that the basic
assumptions of fully-developed flow are satisfied. In axisymmetric geometries, the inflow section must
be perpendicular to the axial direction.
2. Set the conditions at the outer wall (BS_2).
The fluid is assumed to stick to the wall, since at a solid-liquid interface the velocity of the liquid is that
of the solid surface. This is commonly known as the no-slip assumption because the liquid is assumed
to adhere to the wall, and therefore has no velocity relative to the wall.
Retain the default condition Zero wall velocity (vn=vs=0) along BS_2.
3. Set the conditions at the free surface (BS_3).
In a steady-state problem, the velocity field must be tangential to a free surface, since no fluid
particles go out of the domain through the free surface. This constraint is called the kinematic
condition, v_n = 0. This equation requires an initial condition at the starting point of the free surface,
which in this case is located at the intersection of BS_2 and BS_3.
b. Click Free surface.
c. Click Boundary conditions on the moving surface.
Note
Do not select the Outlet option. It is only applicable for die design problems.
d. Select No condition along BS_2 and click Modify.
As mentioned above, the starting point of the free surface is at the intersection of BS_2 and BS_3.
e. Click Position imposed.
f. Click Upper level menu.
g. Click Upper level menu to return to the Kinematic condition menu.
h. Retain the default settings for the Normal force and Direction of motion.
i. Click Upwinding in the kinematic equation.
j. Click Upper level menu to return to the Flow boundary conditions menu.
4. Set the conditions at the flow exit (BS_4).
It is reasonable to consider that a uniform velocity profile is obtained at the exit. In most cases, a bulk
flow is obtained and thus no force is acting, so the selection of zero normal and tangential forces is ap-
propriate. In situations involving pulling velocity or force or gravity, the corresponding boundary condition
should be selected.
b. Click Normal and tangential forces imposed (fn, fs).
c. Accept the default value of 0 for the normal force by clicking Upper level menu.
d. Accept the default value of 0 for the tangential force by clicking Upper level menu.
e. Click No when prompted to confirm that the rotational velocity ( ) is 0.
The rotational force is 0, not the rotational velocity.
f. Click 'w' force imposed.
g. Select 'w' force = constant.
h. Accept the default value of 0 by clicking OK.
i. Click Yes to confirm that the rotational force is 0.
5. Retain the default condition at the symmetry axis (Axis of symmetry along BS_5).
For axisymmetric models, the axis of symmetry is always the y axis. Polydata determines the axis of
symmetry from the mesh file, and automatically imposes the symmetry condition along the line r=0
(x=0).
6. Set the conditions at the boundary of the rotating screw (BS_6).
Since the screw is rotating with angular velocity = 2 = 6.2832 rad/s, the rotational velocity along this
boundary is prescribed to increase linearly with ( = 6.2832 ). In the equation for , X denotes the
direction and Y denotes the direction. Since the fluid sticks to the wall, = 0 = .
b. Click Normal and tangential velocities imposed (vn,vs).
c. Accept the default value of 0 for the normal velocity ( ) and tangential velocity ( ) by selecting
Upper level menu twice.
d. Click No when prompted to confirm that the rotational velocity ( ) is 0.
e. Click Velocity w imposed and select 'w' velocity = linear function of coordinates.
f. Accept the default value of 0 for the constant A by clicking OK.
g. Enter 6.2832 as the New value for the constant B and click OK.
h. Accept the default value of 0 for the constant C by clicking OK.
i. Click Yes to confirm the "w" velocity equation.
j. Click Upper level menu at the top of the Flow boundary conditions menu.
The Global remeshing menu item appears in bold text.
1.9. Step 5: Remeshing

This model involves a free surface for which the position is unknown. A portion of the mesh is affected by
this unknown boundary. Hence a remeshing technique is applied on this part of the mesh. The free surface
is entirely contained within subdomain 2, and hence only subdomain 2 will be affected by the relocation of
the free surface.
Global remeshing
1. Specify the region where the remeshing is to be performed (SD_2).
In some cases, when the mesh is geometrically complex, it may be necessary to split it into additional
subdomains in order to define a specific remeshing method on each of them. For this purpose, Polydata
allows you to create several local remeshings. For the current problem, a single local remeshing is sufficient.
1-st local remeshing
Step 5: Remeshing
a. Select SD_1 and click Remove.
SD_1 is moved from the top list to the bottom list, indicating that only SD_2 will be remeshed.
If you accidentally remove the wrong subdomain, select it and click Add to restore it. Then, follow
the instructions to remove the correct subdomain.
b. Click Upper level menu.
The Method of Spines menu item appears in bold text.
2. Define the parameters for the system of spines.
The purpose of the remeshing technique is to relocate internal nodes according to the displacement of
boundary nodes due to the motion of the free surface. Mesh nodes are organized along lines of
remeshing (spines), which are collections of nodes logically arranged in a one-dimensional manner. This
technique is most suited for 2D extrusion problems. Polydata requires the specification of the first and
last spines that the fluid encounters (inlet of spines and outlet of spines, respectively).
In this case, the inlet of spines is the intersection of subdomain 2 with subdomain 1, and the outlet of
spines is the intersection of subdomain 2 with the flow exit (boundary 4).
Method of Spines
a. Specify the inlet for the system of spines.
Select Intersection with SD_1 and click Confirm.
Step 6: Stream Function
b. Specify the outlet for the system of spines.
Select Intersection with BS_4 and click Confirm.
c. Click Upper level menu twice.
At this point, if you realize that you have made a mistake in global remeshing, click die swell at the
bottom of the menu and perform this Step again.
1.10. Step 6: Stream Function

Once the velocity field is known, Polyflow calculates the stream function automatically. This calculation requires
you to specify the point where the stream function vanishes. Polydata imposes a vanishing value at the
nodal point closest to the specified position.
Assign the stream function
1. Select Condition on the stream function for field 1. Click No in the window that pops up.
2. Enter 5 as the New value of X.
3. Retain the default value of 0 for Y.
4. Click Upper level menu twice.
If you have made a mistake in assigning the stream function, click F.E.M. Task 1 to get into that menu
and then repeat this Step.
Step 8: Save the Data and Exit Polydata
1.11. Step 7: Outputs

After Polyflow calculates a solution, it can save the results in several different formats. Choose the format
that is appropriate for your postprocessor. In this case, save the outputs in the default format for ANSYS
CFD-Post.
Outputs
1. Select Listing: max.
2. Accept the default output option for CFD-Post by clicking Upper level menu.
When exiting the menu, Polydata asks you to confirm the current system units and fields that are to be
saved to the results file for postprocessing.
3. Specify the system of units for the simulation.
a. Click Modify system of units.
b. Select Set to metric_cm/g/s/A+Celsius.
c. Click Upper level menu twice.
If you do not enter the menu Outputs, Polydata will ask you to confirm the current system units at
the end of the session, if it is a new session.
1.12. Step 8: Save the Data and Exit Polydata

After defining your model in Polydata, you need to save the data file. In the next step, you will have to read
this data file into Polyflow and calculate a solution.
Save and exit.
If this was not yet done before (see above), Polydata asks you to confirm the current system units. It will
also ask to confirm fields that are to be saved to the results file for postprocessing.
1. Click Accept.
This confirms that the default Current field(s) are correct.
2. Click Continue.
This accepts the default names for graphical output files (cfx.res) that are to be saved for postpro-
cessing, and for the Polyflow format results file (res).
Step 10: Postprocessing
1.13. Step 9: Solution

In this step, run Polyflow to calculate a solution for the model you just defined using Polydata.
1. Run Polyflow by right-clicking the Solution cell of the simulation and selecting Update from the shortcut
menu.
This executes Polyflow using the data file as standard input, and writes information about the problem
description, calculations, and convergence to a listing file (polyflow.lst).
2. Check for convergence in the listing file.
a. Right-click the Solution cell and select Listing Viewer.
ANSYS Workbench opens the View listing file panel, which displays the listing file.
b. In the View listing file panel, disable the Show only last 200 lines option and click the Manual
refresh button. Then find the SOLVER section that relates to F.E.M. Task 1; at the end of this
section, a message Convergence assumed is displayed. This indicates that the solution has con-
verged. See the Polyflow User's Guide for more information on convergence.
1.14. Step 10: Postprocessing

ANSYS CFD-Post has similar interfaces for UNIX and Windows, the postprocessing steps are illustrated for
Windows.
1. Double-click the Results cell in the ANSYS Workbench analysis and read the results files saved by Polyflow.
ANSYS CFD-Post reads the solution fields that were saved to the results file.
2. Align the view.
a. Right-click a blank area anywhere in the graphical window, and select Predefined Camera from the
shortcut menu, and select View From +Z.
The central mouse button allows you to zoom in and zoom out. The left mouse button allows rotating
the image. The right mouse button allows you to translate the image.
b. Also, right-click a blank area anywhere in the graphical window and deselect Ruler, if needed.
3. Display contours of pressure.
a. Click the Insert menu and select Contour or click the Contour button ( ).
b. Click OK to accept the default name (Contour 1) and open the details view below the Outline tab.
c. In the details view for Contour 1, specify the following settings under Geometry:
i. Next to Locations, click the ellipsis button ( ) on the right and select SD_1_surf and SD_2_surf
(use Ctrl to select multiple items).
Click OK to close the Location Selector dialog box.
ii. Select PRESSURE from the Variable drop-down list, or click the ellipsis button ( ) on the right
and select PRESSURE.
iii. Click Apply.
Figure 1.3: Contours of Static Pressure
d. Restore the symmetry along the Y axis.
i. In the Outline tab, double-click Default Transform.
The details view of Default Transform will open below the Outline tab.
ii. In the details view of Default Transform, disable Instancing Info From Domain.
iii. Disable Apply Rotation.
iv. Enable Apply Reflection.
v. Select YZ plane from the Method drop-down list.
vi. Leave the default value of 0.0[m] for X.
vii. Click Apply.
e. Annotate the display.
i. Click the Insert menu and select Text or click the button.
ii. Click OK to accept the default name (Text 1) and open the details view below the Outline tab.
iii. In the Definition tab of the details view, enter Polyflow Results for Text String.
iv. Possibly check the other tabs (Location, Appearance).
v. Click Apply.
Figure 1.4: Contours of Static Pressure after Mirroring
4. Display velocity vectors.
a. Deselect Contour 1.
b. Click the Insert menu and select Vector or click the Vector button ( ).
c. Click OK to accept the default name (Vector 1) and open the details view below the Outline tab.
d. Perform the following steps in the details view of Vector 1:
i. In the Geometry tab, click the ellipsis button ( ) next to Locations, select SD_1_surf and
SD_2_surf (use Ctrl to select multiple items), and click OK.
ii. Select VELOCITIES from the Variable drop-down list, or click the ellipsis button ( ) on the
right and select VELOCITIES.
iii. Click Apply.
iv. Define the attributes of vectors: in the Symbol tab, set Symbol to Arrow3D and Symbol Size to
5.
v. Click Apply.
e. Remove the annotation.
i. On the Outline tab, under User locations and plots, deselect the item Text 1 previously defined.
The velocity vectors take all components of the velocity into account. Along the screw tip, the rota-
tional component is important, leading to long vectors that are not in the xy plane (perspective view).
After the die exit, a rearrangement of the velocity field takes place. The flow slows down along the
axis of symmetry and accelerates on the outside. This makes the particles go toward the free surface,
creating the swelling.
Figure 1.5: Velocity Vectors
f. Display the mesh.
i. In the Outline tab, select SD_1_surf and double-click.
ii. Under Render tab, deselect Show Faces and select Show Mesh Lines.
iii. Under Color tab, click the ellipsis ( ), select the color white and click OK.
iv. Click Apply.
v. Repeat operations (i) to (iii) for SD_2_surf.
Figure 1.6: Velocity Vectors with Mesh
g. Rotate the whole figure.
i. Move the mouse to the left-hand border of the graphic window until the cursor suggests a rotation
along a vertical line.
ii. Left-click and move the mouse slowly to the right-hand side.
1.15. Summary
This tutorial demonstrated how to set up and solve a 2.5D axisymmetric extrusion problem. It showed
how to set up a free surface problem and the associated remeshing, and demonstrated the use of CFD-
Post to examine the flow behavior associated with the problem.

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Chapter 1: 2.

In this tutorial you will learn how to:

Create a project in ANSYS Workbench.

Start Polydata from ANSYS Workbench.

Create a new task.

Select a remeshing method.

Specify output for CFD-Post.

1.3. Problem Description

Figure 1.1: Problem Schematic

Figure 1.2: Subdomains and Boundary Sets for the Problem

BS1: flow inlet

BS2: outer wall

BS3: free surface

BS4: flow exit

BS5: symmetry axis

BS6: rotating screw

1. Prepare a working folder for your simulation.

2. Go to the ANSYS Customer Portal, https://support.ansys.com/training.

3. Enter the name of this tutorial into the search bar.

a. Click ANSYS Polyflow under Product.

b. Click 15.0 under Version.

5. Select this tutorial from the list.

6. Click Files to download the input and solution files.

The mesh file ext2d.msh can be found in the unzipped folder.

1.5. Step 1: Project and Mesh

b. Save the ANSYS Workbench project using File Save.

c. Enter 2.5-axi-extrusion as the name of the ANSYS Workbench project.

This will create a 2.5-axi-extrusion.wbpj file and a folder named 2.5-axi-extru-

2. Import the mesh file for the Polydata session.

Right-click the Mesh cell and click Import Mesh File.

1.6. Step 2: Models

1. Create a task for the model.

Create a new task

a. Select the following options:

2D 1/2 axisymmetric geometry

b. Click Accept the current setup.

The Create a sub-task menu item appears in bold text.

i. Click Upper level menu to return to the top-level Polydata menu.

iv. Select F.E.M. Task 1.

2. Create a sub-task for the isothermal flow.

a. Select Generalized Newtonian isothermal flow problem.

A small panel appears asking for the title of the problem.

b. Enter die swell as the New value and click OK.

The Domain of the sub-task menu item appears in bold text.

i. Click Upper level menu.

iii. Click Upper level menu.

iv. Select die swell at the bottom of the existing menu.

The Domain of the sub-task menu item appears in bold text.

3. Define the domain where the sub-task applies.

Domain of the sub-task

The Material data menu item appears in bold text.

1.7. Step 3: Material Data

1. Click Shear-rate dependence of viscosity.

2. Click Cross law.

The viscosity is given by the Cross law:

= zero-shear-rate viscosity = 85000

= natural time = 0.2

= Cross law index = 0.3

3. Specify the value for .

Enter 85000 as the New value and click OK.

4. Specify the value for .

Enter 0.2 as the New value and click OK.

5. Specify the value form.

Enter 0.3 as the New value and click OK.