HyperXtrude: Analysis and Design Tool for Extrusion Dies

Altair HyperXtrude is a solution adaptive hp-finite element analysis program for modeling complex fluid flow and heat transfer problems encountered in polymer and metal processing. HyperXtrude is specifically developed to address the needs of polymer and metal extrusion process/product design engineers.

Technology

Benefits

Target Applications

Features

Examples

Demo

Training

Pricing

Contact

Technology

HyperXtrude simulates material flow and heat transfer by solving the Eulerian/Arbitrary Lagrangian-Eulerian form of the governing equations. HyperXtrude uses residual error estimates and local error indicators to identify the flow domain contributing disproportionate shares of error in the real solution. Using the error information, the mesh in these critical regions can be redefined by either refining the elements (h-refinement) and/or enriching the interpolation order (p-enrichment). HyperXtrude uses a combination of these to provide a near optimal hp-finite element mesh to produce accurate results. The resulting adapted meshes are fully unstructured and anisotropic. HyperXtrude is built on the hp-adaptive finite element kernel ProPHLEX. This kernel provides a high level of modularity and modeling flexibility for creating highly customized niche applications for engineering design analysis. HyperXtrude can be customized for specific user needs.

Benefits

One of the key benefits in using the adaptive solution algorithm in HyperXtrude is improved engineering productivity by removing the guesswork inherent with mesh generation. This in turn enables the engineers to solve complex problems more efficiently and accurately than possible by conventional fixed grid techniques.

Target Applications

HyperXtrude is particularly suitable for modeling complex nonlinear problems commonly encountered in the process industry. Typical examples include:

Aluminum Extrusion
Polymer Extrusion
Polymer Processing
Polymer Mixing
Extrusion Die Design
Conjugate Heat Transfer
Fluid Flow and Heat Transfer Through Complex Geometries

Features

The current release of HyperXtrude focuses on modeling incompressible fluid flow and heat transfer problems related to manufacturing processes such as extrusion, polymer melt flow, etc.. The solution algorithm is capable of modeling both low and high Reynolds number (Newtonian and non-Newtonian fluid) flows. Both isothermal and non-isothermal flows can be modeled using HyperXtrude. The non-isothermal feature also allows the user to solve conjugate heat transfer problems.

Analysis Capabilities

Applications

Metal Extrusion

Direct/Indirect extrusion
Heat transfer in tool and workpiece
Steady/time dependent
Moving boundaries
Shape prediction
Free surface calculations

Polymer Processing

Polymer extrusion
Polymer melt flow through complex geometries
Steady/time dependent
Isothermal and non-isothermal
Extrudate swell predictions

Constitutive Models

Metals

Power law
Sine hyperbolic inverse

Polymers

Power law
Spriggs' truncated power law
Carreau model
Cross model
Modified Cross model

Material Properties

Constant
Temperature dependence

Coefficients function of temperature (expression or table)
Exp(Q/RT)
Exp(Tb/T)
Exp(-b(T-To))
WLF

Error Estimates

Residual error estimates
Interpolation error indicators

Adaptivity

Manual and automatic
h-, p-, and hp- adaptivity

Boundary Conditions

Material Flow

Velocity distribution
Specified stresses
Friction at tool-workpiece interface

Heat Transfer

Isothermal surfaces
Prescribed fluxes
Convection and radiation
Volumetric sources

Output

Inside domain

Components of velocity vector
Pressure
Temperature
Strain-rate
Strain
Material properties
Components of stress tensor

On boundaries

Mass flux
Heat Flux
Forces
Average velocity
Average Temperature
Average Pressure

Particle trajectories

Components of velocity vector and their derivatives
Pressure
Temperature and its derivatives
Strain-rate
Strain
Material properties
Components of stress tensor

User Interface

TCL based
User customizable

Pre-processor

HyperMesh

Post-processor

Built-in post-processor
HyperMesh

Graphics & Post-processing

Built-in 3D Interactive GUI
3D iso-surfaces
Velocity vectors
Particle traces
Boundary surfaces
Built-in XY plots along lines
Solution probe
Hard copy output: Postscript, RGB, and Tabular data extraction

Platforms

Unix:

HP: HPUX 10.2
IBM: RS6000 AIX 4.2
SGI: IRIX5.3/6.5
SUN: SUNOS 5.5.1

Linux (Intel)

Red Hat 6.2

Windows (Intel)

Windows NT 4.0
Windows 2000
Windows XP

Examples

	*Polymer Processing*

Extrusion of Square Rod	Profile Extrusion of L-Section	Sheet/Film Extrusion


Flow inside Maddock Mixing Head	Wire Coating Simulation	Design Optimization of Extrusion Dies
	*Metal Forming*

3D Steady State Extrusion of Aluminum Section	Time Dependent Extrusion Simulation	Stea dy State Sheet Rolling Analysis
	*Other Applications*

Channel With Sudden Expa nsion	Conjugate Heat Transfer	Cooling of Electronic Component

HyperXtrude Pricing

The distribution package includes:

Binary executable (node locked)

QA suite of sample problems

Documentation (hard copy and html online)

Technical support

For more information on product pricing, support, engineering services, and training please the nearest Altair Engineering office. We look forward to hearing from you.

HyperXtrude Demo

For more information, please call us at (512) 467-0618 or send an e-mail to us at hxsupport@altair.com

HyperXtrude Training

This training sessions provides extrusion die design and analysis engineers with an introduction to Altair HyperXtrude. Concepts of Adaptive Finite Element Method and their application to the analysis of material flow and heat transfer inside an extrusion die are discussed. This three-day short course covers several HyperXtrude tutorial problems including both 2D and 3D models for steady and time dependent extrusion processes.

Our training room seats eight participants with a dedicated workstation for each individual. The three-day training course will be held at our facilities in Austin. The schedule for training classes is:

March 2002 6 - 8

July 2002 24 - 26

November 2002 13 - 15

Topics covered:

Introduction to hp-Adaptive Finite Element Analysis.
Error Estimation and Adaptivity.
Pre-Processing.
Mesh Generation
Application Boundary Conditions
Analysis.
Post-Processing and Visualization.
Simulation of Steady State Extrusion Problems.
Heat Transfer in Tool and Work piece.
Time Dependent Analysis.
ALE Approach for Time Dependent Problems.

Course Enrollment Form

For more information on the training course please contact the training coordinator.

For information related to accommodation and nearest hotels please contact our office administrator Kathy Tischer.

Contact

North America:	Europe:	Asia and Australia:
Altair Engineering, Inc., 1757 Maplelawn Dr. Troy, MI 48084-4603 Phone: 248.614.2400 Fax: 248.614.2411 e-mail: hxsupport@altair.com URL: http://www.altair.com	Altair Engineering AB IDEON Research Park Scheelev 15, Alfa-Huset S-223 70 Lund SWEDEN Phone: +46 (0) 46 286 20 50 Fax: +46 (0) 46 12 87 45	Altair Engineering, Ltd. Tact No. 4, Bldg. 9F 2-23-12 Minami Ikebukuro Toshima-Ku, Tokyo JAPAN 171-0022 Phone: + 81 3 5396 1341 Fax: + 81 3 5396 1851

Questions, comments or problems regarding this service? webmaster@tx.altair.com.