Extrusion cooking is defined as a combination of thermal and mechanical treatment by which . The first BTP is the starting profile. 0000010001 00000 n Eng. D. Wolf and D.H. White, AIChE J., 22, pp. Elastron provides TPE solutions for different segments which have different technical requirements. Print ISBN: 978-1-56990-775-7. endstream endobj 829 0 obj <>/Metadata 18 0 R/Outlines 23 0 R/PageLayout/SinglePage/Pages 826 0 R/StructTreeRoot 26 0 R/Type/Catalog>> endobj 830 0 obj <>/ExtGState<>/Font<>/ProcSet[/PDF/Text/ImageC]/XObject<>>>/Rotate 0/StructParents 0/Type/Page>> endobj 831 0 obj <>stream K. Luker, paper presented at the Wood Composite Conference, December 56 (2000) 155. 79717976 (2000) 164. 0000003242 00000 n This course involves the students in hands-on troubleshooting of common problems in the plastics extrusion process. These terms and conditions of sale govern the sale by Elastron USA, Inc. to the customer named in the accompanying quotation, order form or confirmation of the goods identified therein, Elastron provides TPE solutions to its global business partners in different sectors and supports them in preparing products that touch daily life.. Meet your TPE solutions partner at K 2022 Plastic Fair. The optimum zone 1 temperature for PP (blue line) is about the same as it is for HDPE (red line). T. Daniels, Thermal Analysis, Anchor Press, London (1973) 8. 142 0 obj <>/Filter/FlateDecode/ID[<4F7FD94C871F4412B5A0219A6C9146D3>]/Index[123 29]/Info 122 0 R/Length 92/Prev 526824/Root 124 0 R/Size 152/Type/XRef/W[1 2 1]>>stream G.M. Gale, Adv. 0000001920 00000 n Definition of Extrusion Process: Extrusion is a compression process in which the work material is forced to flow through a die opening to produce a desired . 263284 (1958) 112. 4 - V. Antonov and A.M. Soutar; Foil Adhesion With Copolymers: Time in the Air Gap, 1991 TAPPI Polymers, Laminations, and Coatings Conference Proceedings, TAPPI PRESS, Atlanta, p.553 Extrusion Process 6.1 Introduction: Extrusion is a compression process in which the work metal is forced to flow through a die opening to produce a desired cross-sectional shape. U.S. Patent 6,136,246, C. Rauwendaal, P. Gramann, B. Davis, T. Osswald (2000) 140. A3.2Extruder Barrel Temperature Profile Optimization 33.5 33.0 Output [kg/h] 32.5 32.0 31.5 31.0 30.5 PP at 50 rpm 30.0 HDPE at 50 rpm 29.5 29.0 190 195 200 205 210 215 220 Barrel Zone 3 Temperature [C] FigureA3.12Output versus barrel zone 3 temperature 9 Pressure [MPa] 8 7 PP at 200C 6 PP at 240C 5 4 3 2 1 0 5 7 9 11 13 15 Axial locaon [D] 17 19 21 23 FigureA3.13Barrel pressures for PP at 50 rpm at two zone 1 temperatures The barrel pressures at 240C are substantially higher than at 200C. hb```VAd`0pTxL'O8940=m& mSDU,>RBgjzPs)WXDtef( 0000026526 00000 n %PDF-1.6 % 57 a Impact extrusion of a. Reduce the barrel temperatures gradually until the right color is achieved. L.A. Utracki and R. Gendron, J. Once the predefined boundary conditions are met (such as a predefined number of iterations), the change of the heating zone takes place. For instance, when we see that the discharge pressure varies at a frequency of 1 Hz and the screw speed is 60 rpm (1 Hz), then the pressure variation is most likely caused by the screw rotation. 0000010964 00000 n Polym. 0000011326 00000 n Sci., 17, pp. The die temperature is too low. C.D. Han and R. Lamonte, Polym. In this situation we are not only losing information, we are actually getting incorrect information about the signal. C. Rauwendaal and K. Cantor, Computer-Based Interactive Training in Extrusion, 56th SPE ANTEC, Atlanta, GA, 340344 (1998), also published in Plastics Engineering, June issue, pp. Eng. 0000004697 00000 n Troubleshooting extrusion problems is one of the most challenging tasks in extrusion operations, requiring a good understanding of the extrusion process and the material properties, good instrumentation, good analysis tools, and a systematic and logical approach. FigureA4.7Column A, time, and column B, amplitude Column B will be the amplitude. FigureA3.25User interface in LabVIEW14 with further documentation For a more detailed description of this work, the readers are referred to the Ph. H.H. Winter, SPE ANTEC, New Orleans, pp. C. Rauwendaal, Unpublished study (1978) 6. 372376 (1962) 15. G. Hiesgen, K. Saul, W. Spitz, and P. Weiss, Pipe cooling simulation for energy savings and enhanced product quality, Proceedings of the Polymer Processing Society 28th Annual Meeting, PPS-28, December 1115, Pattaya, Thailand (2012) 190. (HDPE at 50 rpm) 25 170 180 190 200 210 220 230 240 250 260 270 Barrel Zone 1 Temperature [C] FigureA3.9Output versus barrel zone 1 temperature The discharge melt temperature was measured with a hand-held thermocouple into the extrudate. References 1. The 21 chapters are authored by well-known and experienced engineers who have specialized knowledge about the processes covered in this practical guide. The screw was kept at 50 rpm through all the trials. Fundam., 13, pp. Plasticating Components 2000, a publication from Spirex Corporation, Youngstown, Ohio (2000) 50. 5661 (2019) 225. D. thesis, Entwicklung einer selbstregelnden Zylindertemperatureinstellung auf Basis von Fuzzy-Logik zur Erhhung der Schmelze homogenitt von Einschnecken-extrudern, University of Paderborn (2019) 228. 0000001597 00000 n By using our site, you agree to our collection of information through the use of cookies. In addition, the barrel temperature controller detects whether the temperature setting has already been started and can thus avoid repeated measurement of the same temperature setting. C. Rauwendaal and G. Hiesgen, Analysis of Preheating Extruders, Extrusion 2018 Conference, Cleveland, OH, September 1820 (2018) 204. 120, 07 (2000) 165. C. Rauwendaal and J.F. Ingen-Housz, Intern. Extrusion The Definitive Processing Guide and Handbook. Unsere Partner sammeln Daten und verwenden Cookies zur Personalisierung und Messung von Anzeigen. 315 316 Appendix 3: Extruder Barrel Temperatures FigureA3.19Output versus transition barrel temperatures at 100 rpm These results show that higher temperatures in the transition zone increase extruder output. 321 Appendix 4: Process Signal Analysis Using Fast Fourier Transform When we analyze a process signal in the form of a sine wave, see FigureA4.1, it is easy to see that this signal has a repeating pattern. 0000002448 00000 n P. Gramann, T. Osswald, B. Davis, and C. Rauwendaal, 56th SPE ANTEC, Atlanta, GA, pp. Suranaree University of Technology Jan-Mar 2007 1) Forward extrusion 2) Backward extrusion Metal is forced to flow in the same direction as the punch. 0000021080 00000 n P. Volz, Kunststoffe, 69, pp. Macromol Chem., C16, pp. 6671 (1974) 71. 0000023125 00000 n Sci., 18, pp. 135140 (1975) 86. 0000021579 00000 n A good DAS should have high speed data acquisition capability. 2 Layer uniformity in the machine direction can be influenced by die imperfections, poor die design or adjustment, excessive extruder pressure variation, variable film Soc. A Systematic Approach to Solving Plastic Extrusion Problems. When different causes of variation affect the extrusion process the process signal will become more complicated, see for example FigureA4.2. FigureA4.21Sine wave at frequency 1 Hz sampled at 2Hz 333 334 Appendix 4: Process Signal Analysis Using Fast Fourier Transform If we sample at a frequency lower than 2Hz, then there are not enough samples to capture all the peaks and troughs in the signal. This example shows how the three frequencies that make up the signal shown in FigureA4.2 can be determined through FFT analysis. B. This example has practical implications in actual extrusion operations. J. Becker, P. Bengtsson, C. Klason, J. Kubat, and P. Saha, Intern. Eng. We can repeat the same 329 330 Appendix 4: Process Signal Analysis Using Fast Fourier Transform procedure using a time step size of 1.0 and a sample size of 256. 758771 (1979) 26. FigureA4.19 also shows the frequency spectrum with a time step of 1 second, the blue curve. S.E. Amos, SPE RETEC Techn. FigureA3.22 shows an overview of input and output values for the extruder. This non-uniformity may appear in either the direction of extrusion or tangential to the direction of film production. C. Capone, L. Di Landro, F. Inzoli, M. Penco, and L. Sartore, Thermal and Mechanical Degradation during Polymer Extrusion Processing, Polymer Engineering and Science, Vol. Academia.edu uses cookies to personalize content, tailor ads and improve the user experience. S. Kase, J. Appl Polym. To learn more, view ourPrivacy Policy. REACH is a new European Union regulation concerning the registration, evaluation, authorisation and restriction of chemicals. Elastron designs some special Thermoplastic Elastomer (TPE) grades to meet customer requests for different applications and processes. 601623 (1984) 116. 4243 (1970) 39. J. Perdikoulias, Dimensional Analysis of Extruded Profiles Using a Mobile Phone Camera, Extrusion 2017, October 1820 (2017) 179. C. Rauwendaal, How to Collect and Interpret Process Data in Extrusion, PartII, Plastics Technology, pp. 0000025801 00000 n A melt index of 5.9 g/10min at 21.6 kg load indicates a polymer with a very high melt viscosity. Polymer Processing, VI, 4, pp. W. Michaeli, Extrusion Dies for Plastics and Rubber, 3rd ed., Hanser Publishers, Munich (2003) 173. A. Farahanchi and M.J. Sobkowicz, Kinetic and Process Modeling of Thermal and Mechanical Degradation in Ultra-high Speed Twin Screw Extrusion, Polymer Degradation and Stability, 138, pp. (hc4'qa#j6MgliM":Rn- aiIQ%6L>FNhv6K0;@)AP Then they are added together. After a certain period of time, the pressure and temperature fluctuations are determined. FigureA4.12The value of cell D2 is set to D2=2/4096*IMABS(E2) We now set the values for the FFT frequency in column C. We set C2 = 0, C3=100/4096 (=0.024414063), and C4=0.024414063+C3. 0000004271 00000 n J.F. Agassant, P.D. Anderson, et al., in: I. Manas-Zloczower (Ed.) V. Schppner and V. Resonnek, Determination of the Barrel Temperature Setting of Single Screw Extruders Using Fuzzy Logic, SPE ANTEC, Detroit, March (2019) 227. C.J.S. Petrie and M.M. Denn, AIChE J., 22, pp. W. Knappe and W.D. Mahler, Kunstoff-Rundschau, 19, pp. FigureA3.23Schematic of barrel temperature control The first step is to set a basic barrel temperature profile. %%EOF Troubleshooting: Reduce melt temperature, or if un-melts, increase extruder barrel temperatures Check thermocouple installation and ensure accurate heater control Worn or damaged extruder screw; inspect and measure screw dimensions Worn or damaged extruder barrel; inspect and measure barrel ID D. Dissertation, The Ohio State University, USA, (2004) 170. V. Schppner and V. Resonnek, Einfluss des Zylindertemperaturprofils auf das Prozessverhalten und Strategien zur Ermittlung einer optimalen Temperaturfhrung, Extrusionstechnik 2017: Anlagentechnik und Prozessfhrung 4.0, VDI-Jahrestagung, Kln (2017) 222. This way, measured values can be subsequently reviewed and reconstructed. This will open the Data Analysis window, see FigureA4.8. 219229 (1978) 23. _ At any time, 3 to 6 or more can have a measurable effect on the process. 270 Melt Temperature [C] 260 250 HDPE at 50 rpm 240 PP at 50 rpm 230 220 210 170 180 190 200 210 220 230 240 Barrel Zone 1 Temperature [C] FigureA3.10Melt temperature versus barrel zone 1 temperature 250 260 270 309 Appendix 3: Extruder Barrel Temperatures The very high melt temperatures of HDPE indicate that the extruder screw is not appropriate for this high viscosity polymer. Extrusion problems solved provides responses to more than 300 frequently asked questions about the process of food extrusion and the techniques and equipment involved, in a practical question-and-answer format.The book . Oxidation of resin during shutdown or startup. Michael Browner Troubleshooting extrusion problems is one of the most challenging tasks in extrusion operations, requiring a good understanding of the extrusion process and the material properties, good instrumentation, good analysis tools, and a systematic and logical approach. 1 and 2, Academic Press, New York (1978) 59. Z. Tadmor and I. Klein, Engineering Principles of Plasticating Extrusion, Van Nostrand Reinhold, New York (1970), p. 413 141. 4043, July (2017) 197. Your submission is succesfully completed. C. Rauwendaal, How to Determine Viscosity Data Using a Slit-Die Visco meter part 1, March issue of Plastics Technology, pp. The input range will be the amplitude of the signal. With such a slow data capture rate a significant part of the process variation is not accessible and the graphical information presented to the user is actually wrong! Extruder output tends to increase with transition barrel temperatures as shown in FigureA3.19. These peaks do not reflect the true frequency spectrum reflected by the blue line; these peaks result from a time step that is too large to properly capture the actual variation. K. OBrien, Plast. C.M. Chan, Intern. Change the material in accordance with the die design. This is a distinct drawback of the stepwise approach to barrel temperature optimization because significant information can be lost with the stepwise approach. 862874, July (2011) 231. If the barrel temperature adjustment in zone 1 leads to a decrease of the fluctuations and the fluctuations are now in an area of regular, the next barrel zone will be optimized. % D. thesis, Twente University (the Netherlands) (1988) 185. 12. The decision of the final barrel temperature in the respective zone is chosen by weighting the pressure and temperature fluctuations (5050). J. Vera-Sorroche et al., Infrared melt temperature measurement of single screw extrusion, Polymer Engineering & Science, May (2015) 188. TableA3.2 shows the initial conditions for the extruder. Voids and contamination See "section C & L". 318325 (1991) 145. 385390 (1980) 17. For the plastic material to be conveyed, its friction must be low at the screw surface but high at the barrel wall. 17811785 (1970) 131. I.R. Edmondson and R.T. Fenner, Polymer, 16, pp. P. Weiss, G. Hiesgen, K. Saul, and W. Spitz, Cooling simulation for the prediction of quality properties and production costs of semi-finished extruded products like pipes, Plastics Engineering, June 2014 & SPE ANTEC, April, Las Vegas, Nevada, USA (2014) 192. Sci., 10, pp. The first one is at frequency ~ 0.05, the second one at frequency ~0.16, and the third one at frequency ~ 0.29. ISBN: 1569907765. Adjust die, Adjust volume of air through air ring Adjust temperature Check extruder drive speed. C. Rauwendaal, Dimensional Variation by Melt Temperature Variation in Pipe Extrusion, Extrusion 2015 Conference, Charlotte, NC, November 23 (2015) 209. Extrusion is the process by which a blockbillet of metal is reduced in cross section. Modern extrusion lines should have data acquisition systems (DAS). Check type of antiblock. The resulting spectrum is shown in FigureA4.16. E. Grnschloss, Polymer Single Screw Extrusion: Modeling, Encyclopedia of Materials: Science and Technology, Elsevier Science Ltd., pp. <]>> Sci., 2, 1, (1953) 85. Rheol., 25, pp. ADDIT. FigureA3.22 shows the transmission to a barrel temperature fuzzy controller. Examples of process variables with shortterm variation are melt pressure, melt temperature, and motor load; these are the vital signs of extrusion process. Without the data provided by this system, it would be very difficult to maintain a safe and efficient process and to troubleshoot extrusion problems. Sci., 22, pp. B.H. Maddock, SPE J., 20, 1277 (1964) 143. Knowledge Base, Linguistic Code Input Fuzzification Inference Defuzzification Output FigureA3.21Structure of a fuzzy controller The fuzzy controller consists of three function blocks: fuzzification, inference, and defuzzification. '(l6Q8( 0q !E'AnX/a7cLn H\ N. This book addresses all issues crucial in extrusion troubleshooting. C. Panzera and G.A. Saltzman, Proceedings of the 2nd International Conference on Wear of Materials, pp. FigureA3.24User interface for setting boundary conditions in LabVIEW14 319 320 Appendix 3: Extruder Barrel Temperatures In the next tab, Fuzzy controller, of the user interface, the most important data such as the heating zone, the corresponding heating zone temperature, and the pressure and temperature fluctuations are clearly displayed (see FigureA3.25). FigureA4.19FFT frequency spectrum; blue line: time step 1 second, red line: time step 10 seconds The red curve resulting from a time step of 10 seconds shows six peaks between 0.0 and 0.10. Pages: 371. eISBN: 978-1-56990-776-4. Increase the temperature of the zones that are close to die. Typical screw speeds are one or two orders of magnitude higher. Rheol., 16, 519 (1972) 339 340 References 124. 0000002067 00000 n Select the extruder with a lower L/D ratio for production. 717 (1963) 111. f Z.M?M|Or],^Ov TableA3.2Initial Conditions Used in the Trials Setpoint [C] PP HDPE Barrel zone 1 200 170 Barrel zone 2 210 195 Barrel zone 3 220 220 Die zone 220 220 Screw speed, rpm 50 50 Feed housing cooling on on The solids conveying zone temperature, zone 1, was increased (or decreased) in 10C increments to determine the optimum temperature. The controller is responsible for adjusting the barrel temperature. C. Rauwendaal How to fix vent-flow problems, Troubleshooter, Plastics Technology (2002) 174. 0000009204 00000 n N.C. Wheeler, Annual Conv. FigureA4.10Fourier Analysis window with input and output range filled in When we click OK the following data will show up in column E, see FigureA4.11. The numerator for C3 is the number of time steps per second (Nt=100); it is the reciprocal time step (T). rpm; this corresponds to 35.5 kg/h at 50 rpm. At low screw speed (25 rpm) the effect of feed barrel temperatures on temperature and pressure variation is relatively weak, see FigureA3.17. 59F (1983) 82. (PP at 50 rpm) 26 Poly. C. Rauwendaal, ANTEC 2000, Extrusion Division, Vol. ISBN: 1569907765 Author: Maria del Pilar Noriega E. Format: PDF, ePub, Mobi Category: Technology & Engineering Access Book Description Troubleshooting extrusion problems is one of the most challenging tasks in extrusion operations, requiring a good understanding of the extrusion process and the material properties, good instrumentation, good analysis tools, and a systematic and logical approach. Two extruder screws were used in the study. J.J. Benbow and P. Lamb, SPE Trans, 3, pp. In mathematical terms: (4.2) This theorem can be understood by considering a sine wave at a frequency of 1 Hz, see FigureA4.20. Troubleshooting extrusion problems is one of the most challenging tasks in extrusion operations, requiring a good understanding of the extrusion process and the material properties, good instrumentation, good analysis tools, and a systematic and logical approach. The process stability at 100 rpm is rather poor with the simple conveying screw. In addition to these, the decisions of the fuzzy controllers are made visible in the same line. D. thesis, Technische Hochschule Darmstadt, Germany (1975) 20. Rough Surface Due to Unmelted Particles. Therefore, the setting is adopted, which shows the lowest sum. Appendix 4: Process Signal Analysis Using Fast Fourier Transform FigureA4.9Fourier Analysis window The output range will be the FFT complex. The decisions can be modeled on the temperature change and the mathematical operator. Extrusion process provides a number of benefits over the other production processes. Eng. ), Thermal Characterization of Polymeric Materials, Academic Press, NY (1981) 9. J. 113124 (1982) 37. 311 Appendix 3: Extruder Barrel Temperatures 30 25 HDPE at 170C HDPE at 230C 20 Pressure [MPa] 312 15 10 5 0 5 7 9 11 13 15 17 19 21 23 Axial locaon [D] FigureA3.14Barrel pressures for HDPE at 50 rpm at two zone 1 temperatures The barrel pressures for HDPE follow the same trend as PP with the difference that the pressures at 230C are significantly higher than at 170C. trailer J. 0000026584 00000 n D. thesis of V. Resonnek [227]. FigureA4.15FFT magnitude versus frequency (step size 0.01, Ns=4096) The spectrum shows three distinct maxima. Check water circulation in feed section. This is an algorithm that computes the discrete Fourier transform (DFT) of a sequence. 0000007550 00000 n A viscoelastic material based on low-molecular-weight silanols cured by boric acid, i.e., having a composition similar to that of the well-known Silly Putty, was used to delay sharkskin and stickslip instabilities in the extrusion of linear low-density polyethylene (LLDPE). 0000002517 00000 n T. Osswald, P. Gramann, B. Davis, M. del P. Noriega, and O. Pressure variation over 10% is generally considered unacceptable. Sci., 11, 385 (1971) 106. Rheol., 10, pp. Polym. F.N. Cogswell, J. Non-Newtonian Fluid Mech., 2, pp. British Patent 32559/72 99. 133143 (1997) 163. These conditions were based on common industry practice. 203273 (1986) 91. Polym. In other words, we can only see variations at frequencies less than 0.05 Hz. Eng. This is an important development because it removes the optimization burden from the operator or the process engineer.
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