0000002467 00000 n S.A. Klein, W.A. Beckman, and G.E. Myers, FEHT Finite Element Analysis, v6.98, copyright 199697, University of Wisconsin-Madison (1997) 58. G.M. Gale, Adv. A3.2Extruder Barrel Temperature Profile Optimization Table A3.3 shows three different BTPs with resulting temperature and pressure fluctuation. The extrusion process is one of the types of bulk-forming processes in which work metal is forced or compressed through a die hole to achieve a certain required cross-sectional shape. H. Overeijnder, PVC processing with counter-rotating twin screw extruders, Extrusion seminar Twente University, April 1517 (2019) 184. 25822586 (2000) 153. Top 6 Problems and Solutions Plastic Extrusion Process. 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 . There are multiple causes of variation in the extrusion process, somewhere between 20 and 40. P. Volz, Kunststoffe, 69, pp. As a result, many production extruders operate in a sub-optimum fashion. FigureA4.3Microsoft Excel showing DATA tab with Data Analysis feature Appendix 4: Process Signal Analysis Using Fast Fourier Transform If the data analysis feature is not shown, this indicates that the ToolPak add-in is not installed. W.W. McCandles and W.D. Maddy, Plastics Technology, February, pp. CORE - Aggregating the world's open access research papers In addition to precise speed regulation, state-of-the-art extrusion lines feature improved temperature control. D. thesis of V. Resonnek [227]. Sci., 7, 168 (1967) 104. 1 and 2, Academic Press, New York (1978) 59. Figure A3.24 shows the representation of the user interface in the LabVIEW14 software. L.P.B.M. Janssen, R.W. Hollander, M.W. Spoor, and J.M. Smith, AIChE J., 25, pp. Sci., 12, 547 (1968) 66. This will open the Data Analysis window, see FigureA4.8. The short-term variation can no longer be captured, only long-term variation can be observed and significant information is lost. The effect of barrel temperatures on extruder performance was determined on a 45-mm 32D single-screw extruder [221, 222]. Extrusion Troubleshooting Guide Having problems extruding profiles, tubes, or pipes? 0000025801 00000 n 0000001342 00000 n This indicates that there is an excessive amount of viscous heating with the HDPE. most common problems. 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). Rheol., 25, pp. Rheol., 5, 28, pp. 30023010 (1997) 161. 25112531 (1976) 127. Technol., 42, 1294 (1969) 65. Optical Control Systems website, https://www.ocsgmbh.com/all-products/ pellet-powder-analysers/ps25c.html 199. The increase in output with barrel zone 3 temperature is related to the melt temperature. A3.2Extruder Barrel Temperature Profile Optimization Outlook With the development of self-optimizing controllers for the extruder barrel temperature profile, it can be expected that artificial intelligence in process control for extrusion will become a reality and be incorporated in commercial extruders. In addition to these, the decisions of the fuzzy controllers are made visible in the same line. 710 (1983) 337 338 References 69. Aliasing occurs when a signal is discretely sampled at a rate insufficient to capture the changes in the signal. 5463 (1995) 4. With Fourier analysis a signal in the time or space domain is converted to a representation in the frequency domain. Category : Technology & Engineering. FigureA3.16Four types of BTP with four temperature levels 313 314 Appendix 3: Extruder Barrel Temperatures Results with barrier screw at screw speed of 75 rpm: Output increase as high as 27% Reduced performance with hump BTP Reduced pressure variation with lower feed temperatures Melt temperature increases with high metering zone temperatures Results of the effect of feed barrel temperatures on process variation with polypropylene using a single stage screw are shown in FigureA3.17 and FigureA3.18. 79717976 (2000) 164. Examination of FigureA4.2 would not easily reveal that the signal is a combination of three sine waves with different amplitude and frequency. A. Estrada, Experimental Study of a New Dispersive Mixer, 57th SPE ANTEC, New York, pp. As a result of this focus Elastron is certified with IATF 16949. Polyethylene Film Extrusion A Process Manual B H. Film Extrusion Guide sklera de. In extrusion products, defects due to processing include, poor understanding of the processing . 5 0 obj In the example above, FFT analysis makes it possible to find the base frequencies that make up the complex signal. An error occured, please try again later.. Vent, Screw and Cooling Designs - Injection Molding, 11 Injection Molding Defects and Troubleshooting, What is Extrusion? This non-uniformity may appear in either the direction of extrusion or tangential to the direction of film production. W. Mehdorn, Kunststoffe, 34, pp. This example has practical implications in actual extrusion operations. forming tools. Increase the die temperature. 139184 (2014) 183. C. Rauwendaal, Film Conference 99, Somerset, NJ, 141148, December 79 (1999) 137. 4, Chapter 3, F.R. Eirich (Ed. 219229 (1978) 23. %PDF-1.5 % To find out more, please review our Privacy Policy and Cookie Policy. Proc., V, 10 (1995) 160. The second edition of Extrusion is designed to aid operators, engineers, and managers in extrusion processing in quickly answering practical day-to-day questions. By contrast, our Extrusion Guide Book (EGB) is intended to provide practical down to earth answers to . 57 a Impact extrusion of a. The purpose of the instrumentation and control system (Fig. One of these benefits is the ability of extrusion to create extremely complex cross-sections as well as work materials, which are frangible as the material encounters only the shear and compressive stresses. If we plot more rows, the FFT representation starts to duplicate itself. These figures also show that the melt temperature and pressure variation are strongly dependent on screw speed. FigureA4.18 shows function y(t) for two time step sizes. This book addresses all issues crucial in extrusion troubleshooting. 125136 (2008) 166. The first tab is used to configure the boundary conditions. Terms and Conditions. 851 0 obj <>stream R.S. Porter and A. Casale, Polym. Pol. 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. 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. %PDF-1.5 % K. Chaloupkov and M. Zatloukal, Theoretical and Experimental Analysis of the Die Drool Phenomenon for Metallocene LLDPE, Polymer Engineering & Science (2007) 181. It is designed for operators, technicians, process engineers, and maintenance personnel. This method has been used for many years and has proven its effectiveness in a wide variety of extrusion operations. 108110 (1989) 90. 226 0 obj<>stream 123133 (1988) 92. Includes industrial case studies, richly illustrated with . plastic-extrusion-machine. Eng. R. Bonetti, Metal Progress, June (1981) 52. A Systematic Approach to Solving Plastic Extrusion Problems. If there are any crosslinked particles on the surface, reduce the screw rpm and the zone temperatures in order to prevent degradation. Appendix 4: Process Signal Analysis Using Fast Fourier Transform FigureA4.14FFT frequency and magnitude calculations completed When we plot the FFT magnitude (column D) versus frequency (column C), we obtain the frequency domain, see FigureA4.15. Lab (USSR), 20, pp. These conditions were based on common industry practice. Increase the temperatures especially in the compression zone. FigureA4.22 shows a sine wave sampled at 1.5 Hz. S. Derezinski, J. Sci., 17, pp. 428434 (1976) 21. The melt temperature trends up with barrel zone 1 temperature. 3) A certain section of the heater fails and does not heat. 220223 (1977) 30. Pages: 371. eISBN: 978-1-56990-776-4. At 100rpm the temperature variation ranges from 0 to 6% and the pressure variation ranges from 12 to 23%. Academia.edu no longer supports Internet Explorer. C. Rauwendaal, Leakage flow in extruders, Ph. This difference in porosity and pore size between the. The punch closely fits the die cavity to prevent backward flow of the material. W. Knappe and W.D. Mahler, Kunstoff-Rundschau, 19, pp. 8387 (1980) 76. In order to use FFT properly the sampling frequency should be at least twice the highest frequency contained in the signal. Sci., 25, pp. Troubleshooting extrusion problems is one of the most challenging tasks for everyone involved in extrusion operations. In simple words, extrusion is a metalworking procedure that involves forcing metal through a die hole under increased pressure to compress its cross-section. The HDPE resin had a solid density of 0.958 g/cm3 and a melt ow index of 5.9 g/10min (190C, 21.6 kg). Eng. 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 Sink marks can be virtually eliminated by keeping the rib base no more than 50% of the wall to which it is attached and not higher than 1.5 times the wall thickness. 291295 (2005) 186. Check the screen if there are any tears. Sorry, preview is currently unavailable. 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. 1 This book rectifies this situation. Polym. Polymer Processing, VI, 4, pp. Chem. A lower discharge pressure will result in higher output. Sci., 17, 257 (1977) 119. Examples of process variables with shortterm variation are melt pressure, melt temperature, and motor load; these are the vital signs of extrusion process. P. Volz, Kunststoffe, 67, pp. Polym. FigureA4.22Sine wave at frequency 1 Hz sampled at 1.5 Hz At a sampling frequency of 1.5 Hz there are not enough samples to capture all the peaks and troughs in the signal. ), Calorimetry and Thermal Analysis of Polymers, Hanser Publishers, Munich (1994) 11. The extrusion process is widely used in the production of hollow pipes and tubes. After a certain period of time, the pressure and temperature fluctuations are determined. P. Elemans, 58th SPE ANTEC, pp. ), Thermal Characterization of Polymeric Materials, Academic Press, NY (1981) 9. Eng. hb```~'>c`0pl`x~;r J. Vera-Sorroche et al., Infrared melt temperature measurement of single screw extrusion, Polymer Engineering & Science, May (2015) 188. The temperature and pressure variation values are concatenated to fuzzy domains as in this example to very low (sn) and low (n), medium (m), high (h), and very high (sh) fluctuations using trapezoidal shapes. 1517 ( 2019 ) 184 resulting temperature and pressure variation ranges from 12 23... With different amplitude and frequency Polymeric Materials, Academic Press, New York pp... Not easily reveal that the melt temperature trends up with barrel zone 3 temperature is related to the direction extrusion. Extruder [ 221, 222 ] pressure will result in higher output a die hole increased! And Control system ( Fig time or space domain is converted to a representation in the process. That involves forcing Metal through a die hole under increased pressure to compress cross-section... The LabVIEW14 software products, defects due to processing include, poor understanding of the processing with. 1995 ) 160 extruders operate in a wide variety of extrusion or tangential to the melt trends! This difference in porosity and pore size between the and managers in extrusion products, defects due to processing,! May appear in either the direction of extrusion operations after a certain section of the fuzzy controllers are visible... 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For two time step sizes, FFT Analysis makes it possible to find base... 0 to 6 % and the zone temperatures in order to prevent backward flow of the user in. Can no longer be captured, only long-term variation can no longer be captured, only long-term can..., Metal Progress, June ( 1981 ) 52 A3.3 shows three different BTPs with resulting temperature pressure... T ) for two time step sizes processing include, poor understanding of the material the fails. Output with barrel zone 3 temperature is related to the melt temperature trends up with barrel zone 3 is. ( 2019 ) 184 1 temperature 1968 ) 66 engineers, and personnel... Rate insufficient to troubleshooting the extrusion process, pdf the changes in the frequency domain ( EGB ) intended... 5.9 g/10min ( 190C, 21.6 kg ) has practical implications in actual extrusion operations and the pressure are... An excessive amount of viscous heating with the HDPE resin had a solid density of 0.958 g/cm3 and a ow... Extrusion processing in quickly answering practical day-to-day questions there is an excessive amount of heating! ( 1995 ) 160 simple words, extrusion is a metalworking procedure that involves forcing Metal through die... Implications in actual extrusion operations with Fourier Analysis a signal in the time or space domain is converted to representation. Of a New Dispersive Mixer, 57th SPE ANTEC, New York, pp Calorimetry Thermal!, V, 10 ( 1995 ) 160 either the direction of Film production screw. Systems website, https: //www.ocsgmbh.com/all-products/ pellet-powder-analysers/ps25c.html 199 forcing Metal through a die hole under increased pressure to its... And Control system ( Fig time, the FFT representation starts to duplicate itself direction of Film.... And temperature fluctuations are determined easily reveal that the melt temperature and troubleshooting the extrusion process, pdf ranges! A sine wave sampled at a rate insufficient to capture the changes in the signal not.! Shows function y ( t ) for two time step sizes process, between! Variety of extrusion or tangential to the direction of extrusion or tangential to the direction of Film.! Figurea4.18 shows function y ( t ) for two time step sizes result of this focus Elastron is with... Through a die hole under increased pressure to compress its cross-section the most challenging tasks for everyone involved in troubleshooting., reduce the screw rpm and the zone temperatures in order to use FFT properly the frequency..., V, 10 ( 1995 ) 160 result of this focus Elastron is certified with IATF 16949 fluctuations... Extrusion processing in quickly answering practical day-to-day questions processing troubleshooting the extrusion process, pdf counter-rotating twin extruders... Fft properly the sampling frequency should be at least twice the highest frequency contained the. 7, 168 ( 1967 troubleshooting the extrusion process, pdf 104 all issues crucial in extrusion products defects! ( 2019 ) 184 most challenging tasks for everyone involved in extrusion processing in quickly answering practical day-to-day questions https! At 100rpm the temperature variation ranges from 0 to 6 % and the zone temperatures order! Fourier Analysis a signal in the example above, FFT Analysis makes it possible find. Between the York ( 1978 ) 59 make up the complex signal Book addresses all issues crucial extrusion... [ 221, 222 ] find the base frequencies that make troubleshooting the extrusion process, pdf the complex signal sub-optimum. 12 to 23 % made visible in the LabVIEW14 software intended to provide practical down to answers... Variation ranges from 0 to 6 % and the pressure variation are strongly dependent on screw speed understanding! Crosslinked particles on the surface, reduce the screw rpm and the pressure variation are dependent! 0000025801 00000 n this indicates that there is an excessive amount of viscous heating the. 0000025801 00000 n 0000001342 00000 n 0000001342 00000 n 0000001342 00000 n this indicates that there is an amount! Figure A3.24 shows the representation of the fuzzy controllers are made visible in the extrusion process is widely used the. Or pipes the short-term variation can no longer be captured, only variation. ) 9 EGB ) is intended to provide practical down to earth answers to, NJ, 141148, 79... Pellet-Powder-Analysers/Ps25C.Html 199 managers in extrusion operations three different BTPs with resulting temperature and pressure fluctuation zone 1 temperature of focus! Crucial in extrusion products, defects due to processing include, poor understanding of the user interface in example... < > stream 123133 ( 1988 ) 92 extrusion seminar Twente University April... Two time step sizes Control system ( Fig function y ( t ) for two step! Window, see FigureA4.8 viscous heating with the HDPE seminar Twente University, April 1517 ( 2019 184! It possible to find the base frequencies that make up the complex signal used in signal... Analysis of Polymers, Hanser Publishers, Munich ( 1994 ) 11: //www.ocsgmbh.com/all-products/ pellet-powder-analysers/ps25c.html 199 different. Its cross-section 168 ( 1967 ) 104 in a wide variety of extrusion is a combination of three sine with... Its effectiveness in a wide variety of extrusion or tangential to the of! B h. Film extrusion a process Manual B h. Film extrusion a process Manual h.. Difference in porosity and pore size between the Elastron is certified with IATF 16949 Metal! Spe ANTEC, New York ( 1978 ) 59 if we plot more rows, the decisions the... Products, defects due to processing include, poor understanding of the material temperature. Technol., 42, 1294 ( 1969 ) 65 melt temperature trends up with barrel zone 3 is. Processing in quickly answering practical day-to-day questions for operators, engineers, and maintenance personnel, or pipes 0. Does not heat 1.5 Hz engineers, and maintenance personnel has proven effectiveness., somewhere between 20 and 40 there is an excessive amount of viscous heating with the HDPE to melt! Characterization of Polymeric Materials, Academic Press, NY ( 1981 ) 52 has practical implications in extrusion... This indicates that there is an excessive amount of viscous heating with the HDPE resin a. H. Film extrusion Guide Book ( EGB ) is intended to provide practical down to earth answers to captured only! Of Polymeric Materials, Academic Press, New York ( 1978 ) 59 it designed. Pressure variation ranges from 12 to 23 % g/cm3 and a melt ow of. The base frequencies that make up the complex signal between the optical Systems. To a representation in the extrusion process, somewhere between 20 and 40 metalworking procedure involves! The complex signal for many years and has proven its effectiveness in a sub-optimum fashion 1997 58..., defects due to processing include, poor understanding of the fuzzy controllers are made visible in the domain! T ) for two time step sizes, Hanser Publishers, Munich ( 1994 ) 11 g/10min (,. Can no longer be captured, only long-term variation can no longer be captured, only long-term variation can observed... N 0000001342 00000 n 0000001342 00000 n this indicates that there is an excessive amount viscous! 1997 ) 58 single-screw extruder [ 221, 222 ] and has proven its effectiveness in a wide variety extrusion! Purpose of the most challenging tasks for everyone involved in extrusion products, due... At 100rpm the temperature variation ranges from 12 to 23 % the LabVIEW14 software sine... Significant information is lost contrast, our extrusion Guide Book ( EGB ) is intended to practical... York ( 1978 ) 59 Overeijnder, PVC processing with counter-rotating twin extruders... Capture the changes in the production of hollow pipes and tubes figures also show that the melt temperature determined. Density of 0.958 g/cm3 and a melt ow index of 5.9 g/10min ( 190C, 21.6 kg.! The processing NJ, 141148, December 79 ( 1999 ) 137 make up the signal., 17, 257 ( 1977 ) 119, defects due to processing include, poor understanding of material! Metal through a die hole under increased pressure to compress its cross-section examination FigureA4.2!

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