% IMPORTANT: The following is UTF-8 encoded. This means that in the presence
% of non-ASCII characters, it will not work with BibTeX 0.99 or older.
% Instead, you should use an up-to-date BibTeX implementation like “bibtex8” or
% “biber”.
@PHDTHESIS{Sasse:1005559,
author = {Sasse, Jana},
othercontributors = {Hopmann, Christian and Behr, Marek},
title = {{A}djoint topology optimisation of polymer melt flow
channels producible by additive manufacturing},
school = {Rheinisch-Westfälische Technische Hochschule Aachen},
type = {Dissertation},
address = {Aachen},
publisher = {RWTH Aachen University},
reportid = {RWTH-2025-01844},
pages = {1 Online-Ressource : Illustrationen},
year = {2025},
note = {Veröffentlicht auf dem Publikationsserver der RWTH Aachen
University; Dissertation, Rheinisch-Westfälische Technische
Hochschule Aachen, 2025},
abstract = {The design of polymer melt flow channels in extrusion lines
remains challenging, leading to an increased use of
optimisation algorithms. Additive manufacturing increases
the degrees of freedom in flow channel design, but its
manufacturing constraints must be considered. This thesis
aims to investigate the potential of adjoint topology
optimisation for designing polymer melt flow channels for
specific optimisation objectives while ensuring additive
manufacturability. This includes an investigation of the
operating point dependency of the optimisation algorithm. An
algorithm is developed to perform adjoint topology
optimisation in OpenFOAM (OpenFOAM Foundation Ltd., London,
UK). It uses an immersed boundary representation to enable
quick adaptation of the geometry. The algorithm is extended
with additional constraints ensuring additive
manufacturability on non-cartesian meshes. Different
optimisation objectives facilitate the targeted optimisation
for minimal pressure drop or maximal flow balance, thermal
mixing, or material mixing. The algorithm is demonstrated in
two use cases. In the first use case, a static mixer is
optimised for minimal pressure drop, maximal thermal mixing,
and material mixing. The operating point dependency of the
optimisation algorithm is investigated by evaluating the
performance of the static mixers before and after
optimisation for off-design operating points. The best
candidate static mixers are manufactured and evaluated in
lab trials. In the second use case, a simple L-profile
extrusion die flow channel is optimised for either minimal
pressure drop or maximal flow balance. The algorithm
improves the flow channels' functionality with respect to
their optimisation objective while ensuring suitability for
additive manufacturing. In the static mixer use case, all
optimisation objectives achieve a pressure drop reduction,
which is confirmed qualitatively in lab trials. The
optimisation results are independent of the operating point
regarding the throughput and polymer material but highly
dependent on the inlet inhomogeneity. Optimisation for
minimal pressure drop is the most reliable independent of
the operating point. In the extrusion die use case, both
optimisation objectives reduce the pressure drop, but only
the optimisation for flow balance improves flow balance.
This research highlights the optimisation potential for
individualised mixing elements and demonstrates the
potential of adjoint topology optimisation as a method for
designing the flow channels of complex profile extrusion
dies.},
cin = {417810},
ddc = {620},
cid = {$I:(DE-82)417810_20140620$},
pnm = {IGF21298N - Schnelle automatische Optimierung von
statischen Mischern für die Extrusion von Kunststoffen
mittels der Methode der Lagrange-Multiplikatoren zur
Anwendung auf konventionellen Rechnersystemen (21298N) /
WS-B2.III - Continuous Production (X080067-WS-B2.III) / DFG
project G:(GEPRIS)390621612 - EXC 2023: Internet of
Production (IoP) (390621612)},
pid = {G:(BMWK)21298N / G:(DE-82)X080067-WS-B2.III /
G:(GEPRIS)390621612},
typ = {PUB:(DE-HGF)11},
doi = {10.18154/RWTH-2025-01844},
url = {https://publications.rwth-aachen.de/record/1005559},
}
guest ::