CAEFF Integrated Model
Process Simulation Package

The CAEFF software engineering group is developing simulation tools capable of predicting final properties for a given polymeric material in an industrial fiber or film process. CAEFF models will ultimately incorporate the entire spectrum of fiber and film process stages, which include melting and mixing, filtration, forming, external flow under quench conditions, and drawing and take-up.

The Integrated Model seeks to provide a mathematical analysis of the entire extrusion process - from the filter region, to the fiber-spinning region, all the way to the post-draw region. Running via a wizard interface, it is highly extensible, meaning that it can support other computer models as technological advancement proceeds. The user designs a process to execute, composed of one or more models about the various regions. The user then customizes the model, via user-friendly interfaces, with the polymer and model information. All the models are executed at once, and results are distributed to several pages, each with graphical displays depicting the data.

The prototype code incorporates filtration, forming, external flow under quench conditions, and drawing, applied to fiber melt-spinning. Fluid constitutive models, such as Newtonian, Carreau, Oldroyd-B, and Giesekus, as well as the process conditions (e.g., temperature-dependence and die-swell) are included.

Visualization plays a prominent role, providing a user-friendly means for initializing, monitoring, and post-processing simulation output. The process stages are integrated using a component-based design so that configurations representing all or part of a process stage can be easily swapped in and out. The framework that builds these processes is primarily written in C++, but also uses C and FORTRAN. Generative programming techniques are used to overcome degradation in the performance and memory which is often associated with the C++ language.

Each model features a user-friendly, interactive interface to provide an accurate description of the process.	Each model's results are depicted with vivid displays.