Optimization of Degradable Polylactic Acid-Based Coating Materials for Sustainable Wire Manufacturing Injection Process Using Computational Fluid Dynamics Analysis

Abstract

This study investigates the impact of injection angle on polylactic acid (PLA) wire coating performance, focusing on flow dynamics, heat transfer, mass density, and pressure distribution. Three angles: 30°, 45°, and 60° were assessed for their effects on coating characteristics. At 30°, the flow is smooth with minimal turbulence, ensuring consistent deposition. The 60° angle increases velocity and material penetration but risks turbulence and uneven coating. The 45° angle optimally balances material mixing and flow stability. In terms of heat transfer, the 30° angle concentrates heat near the injection point, creating a steep thermal gradient, while the 60° angle disperses heat more broadly but with lower intensity. The 45° angle ensures uniform heat distribution, improving energy efficiency. Regarding mass density, the 30° angle favours localized deposition, ideal for concentrated applications, while the 60° angle promotes broader distribution with reduced concentration. The 45° angle optimises density uniformity and maintains structural integrity. Pressure distribution follows similar trends, with 30° and 60° angles causing uneven deposition, whereas the 45° angle ensures balanced pressure distribution. In conclusion, the 45° angle offers superior performance across all parameters, providing an optimal balance of efficiency, uniformity, and structural integrity, thus enhancing PLA wire coating quality for sustainable engineering applications.