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Computational modeling of optical fiber manufacture

The key for optical fiber manufacturers to remaining profitable in today’s environment is cost reduction, requiring a hard look at raw material and processing costs to evaluate areas for savings and materials reduction. In this paper we examine the use of computational fluid dynamics (CFD) as a tool to study fiber-manufacturing processes. Specific examples are given of the use of CFD to analyze the consumption of helium as a coolant gas in fiber drawing, with the objective of showing that helium usage can be reduced by either optimizing the operation of existing cooling tubes or through improved cooling tube designs. With respect to the drawing of optical fiber, the cooling tubes should be ideally operated at their most efficient conditions such that the cooling capacity requirement is satisfied with minimum usage of cooling gas (e.g., helium). Optimization of the fiber cooling process can be realized by evaluating the cooling efficiencies of different designs of cooling tubes, and under different operating conditions. The use of CFD simulation can avoid mistakes and reduce the cost and time of process development.