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Two optimization problems are formulated to improve the effectiveness and productivity of pultrusion processes, to preserve the quality of pultruded profiles, and to take into account the ambient industrial shop temperature and requirements of process technologists. To solve these problems, an optimization methodology using designed computer experiments and the response surface technique was developed. The effects of room temperature and curing allowed behind the die exit on the energy consumption and pull speed were investigated. A more accurate and realistic process optimization was achieved by the temperature control strategy with heater switch-on and -off operations. This indirect optimization methodology allowed us to develop interactive technological maps on the basis of an accessible-to-all Excel code for technologists working in industrial shops. As an example, demonstrating the effectiveness of the methodology developed and utilization of the interactive technological map, the optimization of a real pultrusion process, producing two rod profiles with ears simultaneously, is carried out. [ABSTRACT FROM AUTHOR]

The necessary composition and content of fillers of a multicomponent extrudable composition based on an ultrahigh-molecular polyethylene (UHMPE) with specified mechanical and tribotechnical characteristics are determined. For the purpose of effective and operational development of extrudable composites based on an UHMPE, a minimum amount of experimental data and an algorithm for determining the governing parameters (formulations) is used, which give the needed (restrictive) values for the effective characteristics of multicomponent polymer-polymer compositions. This allows one to secure the tribological, mechanical and technological properties required. The limited amount of experimental data for the relation between the effective properties and the formulation required is supplemented by values calculated using the Lagrange interpolation polynomial. The relations obtained are represented as surfaces and the corresponding level lines. The imposition of level lines allows one to determine the area that meets the requirements specified and to find the formulation necessary for it. On the basis of this algorithm, the optimum formulation of a three-component mixture consisting of an UHMPE, a high-density polyethylene grafted with maleic anhydride, and a polypropylene having tribomechanical properties at the level of an UHMPE, but with a melt flow-behavior index suitable for 3D printing by fused deposition modeling, is determined. According to the formulation found, samples were made and tested, and they completely satisfied the properties prescribed. [ABSTRACT FROM AUTHOR]