Background: In the fabrication of high-quality glass fibres, the extrusion process plays a crucial role in defining the final internal geometry and optical properties of the material. In this project, the glass is first 3D-printed from quartz glass powder, followed by burnout of organic components and subsequent sintering to obtain different cross-sectional geometries. These geometries directly influence light reflection and transmission characteristics. To better understand and predict the outcome of such extrusion processes, numerical modelling can be employed. By treating the molten glass as a Newtonian fluid, the process can be simulated using well-established finite volume methods (FVM). The aim of this thesis is to develop a validated numerical model and a predictive tool capable of linking initial geometry and process parameters to the resulting extruded shape.
Tasks:
- Conduct an extensive literature review on glass flow modelling, extrusion processes, and existing numerical approaches.
- Set up and perform CFD simulations of the extrusion process using STAR-CCM+.
- Perform Design of Experiments (DOE) and sensitivity analyses to study the influence of various boundary conditions.
- Generate and analyse a comprehensive dataset for different process and geometric configurations.
- Conduct statistical analysis of simulation results to support the development of an in-house predictive tool for extrusion outcomes.
- Perform post-processing, comparison with literature and available experiments, and validation of numerical results.
Requirements:
- Background in Fluid Mechanics, Mechanical Engineering, or Computational Engineering.
- Experience with CFD and finite volume methods (knowledge of STAR-CCM+ is advantageous).
- Proficiency in programming and data analysis (Python, C/C++, MATLAB, etc.).
- Strong analytical and communication skills.
- Interest in interdisciplinary research at the interface of materials science and fluid dynamics.
- Ability to work independently and self-motivated.
Supervisors:
Dr. Michael Frosch
Prof. Dr. Andreas Wierschem
Professors