This case study highlights the entire design and testing process, virtual prototyping, of an extruded automotive aluminum reinforced rubber seal. First, the expected deformation of two similar shapes of the rubber seal will be analyzed. The design that will result in a more uniform deformation and hence better sealing performance will be chosen for production. Then, to obtain the required extrusion die profile that will be used to manufacture that seal shape, the process of inverse die design will be implemented. In this procedure, the final seal cross section is used to obtain what the required die lip shape should be so that after die swell the final profile is obtained. Finally, to verify the entire die performance, detailed flow analysis is carried on the entire extrusion die and the flow balance is verified.
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