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11 Extrusion
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Extrusion
MFG 355
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Click frame to play video
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Extrusion
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Extrusion System
Cutter/Winder Puller
Water Bath
Extruder
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Extruder
BarrelMotor
Hopper
Feed
Feed throat
Heating zones
Die
LinkageThrust bearing
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Extruder
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Drive Motor
• Turns the Screw
• Provides power for the process
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Thrust Bearing
• Prevents the screw from moving backward
• Seals off the end of the barrel
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Extruder Screw
• Connected to drive linkage
• Inside barrel
• Grinds the plastic
• Moves the plastic
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Extrusion Screws
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Extrusion Screws
• L/D ratio– Relates directly to the extruder’s ability to mix– Typical L/D ratio is 16:1 up to 32:1
• Newer machines tend to have higher ratios
Length (L)
Diameter (D)
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Extrusion Screws
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Extrusion Screws
Flight Depth
RootDiameter
ScrewDiameter
Pitch Ө
BarrelDiameter
Material Feed Direction
Pitch Angle
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Extrusion Screws
• Zones
Material Flow
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Extrusion Screws
• Varying screws for different resins/applications
Polyethylene Screw
Cold Feeder Stuff Screw
Food Industry Screw
Feed Compression Metering
Material Flow
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Multi-Screw and Multi-Barrel
• Valuable in heat sensitive material processing (PVC)
• Increases efficiency in moving material
• More positive pumping action
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Multi-Screw and Multi-Barrel
• Co-Rotating Screws
• Counter-Rotating Screws
• Advantages and Disadvantages
Co-Rotating Screws Counter-Rotating Screws
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Head Zone
• The portion of the machine at the end of the barrel
• Holds/contains the die
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Head Zone
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Head Zone
• Breaker plate– Screens– Filters
• Adaptor– Die mount
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Adaptor
• Laminar flow or turbulent flow
Extruder end
Die end
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Adaptor
• Laminar flow or turbulent flow
Material Flow
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Die
• The “mold” for the extrusion process
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Die
Input (machine) side Output side
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Die
• Dies are cut to produce a certain profile
• Cutout will probably not match the finished product
DiePart
Part
Die Die
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Spider Die
Adjustment Pins
Material Flow
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Spider Die
Material Flow
Adjustment pinAdjustment pin
MaterialMandrel
Die wall
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Spider Dies
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Coat Hanger Dies
• Correct flow– Velocity– Distribution
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Wire Coating Dies
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Wire Coating Dies
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Wire Coating Dies
Bare Wire Input
Insulated WireOutput
Heat UnitExtruder
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Dimensional Control
Sizing Plates
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Part Dimension Control
• Die
• Sizing plate
• Air pressure
• Cooling (shrinkage)
• Speed of pull
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Pullers
Cutter/Winder
Puller
Water Bath
Extruder
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Pullers
• Pullers are in contact with cooled material
• Pulling quicker will decrease the cross-sectional area of the extrudate
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Film Blowing
• Extrude a “tube” upwards through vertical die
• Inflate “tube” till it becomes a film
• Collect film and process as needed
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Film Blowing
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Film Blowing
Extruder
Die/Blower Assembly
Sizing Basket
Nip Rollers
Windup
Frost Line
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Film Blowing
• Film Blowing Systems
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Film Blowing
Extruder and Blower
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Film Blowing
• Dies
Envelope Sensor
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Film Blowing
• Printing/Cutting/Sorting
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Film Blowing
Film Folders/Rollers
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Coating of Paper and Fabric
• Extrude a film
• System of rollers to apply extruded film to paper/fabric
• Windup rollers take up coated paper/fabric
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Calendering
• Extrude to a system of rollers
• Material is flattened/spread to desired specifications
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Fiber Extrusion
• Extrusion through an extruder
• Spun and stretched as filaments exit the die
• Twisted/wound and/or taken up on a roll
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Fiber Extrusion
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Post Extrusion Forming
• Corrugated pipe
• Perforated pipe
• Bell ended pipe
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Coextrusion
• Join two streams of molten plastic into one
• Separate extruder for each stream (typically)
• Allows for multiple layers from different materials
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Extrusion Problems
• Melt fracture
• Sharkskin or alligator hide
• Uneven flow and surging
• Degradation
• Poor mixing
• Contamination
• Bubbles in extrudate
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Melt Fracture
• Laminar flow or turbulent flow
Material Flow
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Melt Fracture
• Laminar flow or turbulent flow
Material Flow
Die
Material
Material
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Sharkskin or Alligator Hide
• Uneven or poor surface finish
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Uneven Flow and Surging
• Cause cross-sectional variation
• Cause wall thickness variation
• Depending on the parts this can cause premature failure
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Degradation
• Discoloration
• Weakening
• Speckling
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Poor Mixing
• Streaks of coloration
• Particles
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Bubbles in the Extrudate
• Excessive moisture
• Absorbed volatiles
• Severe degradation in the presence of moisture– PET, PC, Nylon
• Air entrapment
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Thank You
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Extruder