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Dynamics simulation and product quality consistency optimization of energetic material extrusion process

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Abstract

This study addresses the issue of quality consistency in the extrusion process of energetic materials using multi-channel dies. To improve the extrusion efficiency of single-base energetic materials, a multi-channel die approach is utilized to yield more products in one extrusion. However, this method may compromise quality consistency during the process. Consequently, the finite element method (FEM) was employed for dynamics simulation of the extrusion process in the multi-channel die and further analysed the impact of critical parameters, such as extrusion speed and channel position, on product quality consistency. A strong linear relationship between flow parameters and \({d}_{c}\), the average distance from each channel to the center of the die outlet plane, was reveal from simulation results. An optimization method based on channel distribution was proposed, and the product quality consistency ratio was calculated by averaging the shape consistency ratio, surface quality consistency ratio, and density consistency ratio. Simulation results indicate that this method effectively improves product quality consistency without significantly compromising extrusion efficiency. However, while increasing piston speed can also enhance product quality consistency, it will raise the extrusion pressure, thus increasing the risk of energetic material burning. Overall, this research provides new theoretical underpinnings and practical methods for optimizing the extrusion process of energetic materials. The basic theory, formula, algorithm, and simulation will be presented to validate the correctness and feasibility of the proposed method.

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Data sharing not applicable, as this article describes a method of dynamics modeling and analysis, and the data supporting this study has been available within the article.

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Funding

The research was supported by the National Natural Science Foundation of China (Grant No: 11972193, 92266201).

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Authors and Affiliations

  1. Institute of Launch Dynamics, Nanjing University of Science and Technology, Nanjing, 210094, P.R. China

    Jingyu Zou, Bao Rong, Yibo Liu, Xiaoting Rui & Guoping Wang

  2. National Key Laboratory of Complex Multibody System Dynamics, Nanjing University of Science and Technology, Nanjing, 210094, P.R. China

    Jingyu Zou, Bao Rong, Yibo Liu, Xiaoting Rui & Guoping Wang

Authors
  1. Jingyu Zou
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  2. Bao Rong
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  3. Yibo Liu
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  4. Xiaoting Rui
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Contributions

All authors contributed to the study conception and design. Rheological experiment, extrusion tests, data collection, CFD computation, and analysis were performed by Jingyu Zou, Bao Rong. Material preparation, data collection were performed by Xiaoting Rui and Guoping Wang. The CAD modelling were performed by Yibo Liu. The first draft of the manuscript was written by Jingyu Zou and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Bao Rong.

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Zou, J., Rong, B., Liu, Y. et al. Dynamics simulation and product quality consistency optimization of energetic material extrusion process. Int J Adv Manuf Technol 131, 1497–1514 (2024). https://doi.org/10.1007/s00170-024-13185-8

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  • DOI: https://doi.org/10.1007/s00170-024-13185-8

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