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Processing of Polymers and Composites: Lecture 13 - 03/02/2020

The document discusses various processing methods for polymers and composites using extrusion, including producing granules, profiles, films, pipes and other extruded goods. Extruders can be used to melt, mix and form raw materials into a continuous output through dies. Process variables like screw speed, temperature and die geometry impact the output rate and properties of the extruded materials.

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MK Saravanan
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42 views

Processing of Polymers and Composites: Lecture 13 - 03/02/2020

The document discusses various processing methods for polymers and composites using extrusion, including producing granules, profiles, films, pipes and other extruded goods. Extruders can be used to melt, mix and form raw materials into a continuous output through dies. Process variables like screw speed, temperature and die geometry impact the output rate and properties of the extruded materials.

Uploaded by

MK Saravanan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Processing of Polymers and Composites

Lecture 13 – 03/02/2020

Dr S. Gowthaman
Indian Institute of Information Technology Design and Manufacturing Kancheepuram
Chennai - 600127
Analysis of Flow
Analysis of Flow

Leak Flow
Analysis of Flow
Analysis of Flow
When all other parameters are kept constant, the figure below shows the variation of
output with respect to helix angle
Extruder / Die Characteristics
Case 1 - free discharge where there is no pressure build up at the end of the extruder
(no die - Open Discharge)

Case 2 - the pressure at the end of the extruder is large enough to stop the output
(die plug - Closed Discharge)
Extruder / Die Characteristics
Variation of Q with respect to P: Qmax and Pmax are shown as the limits of the screw
characteristic.
The output from the die is given by the relation

Extruder output Die output

At the operating point, the die output and the extruder output will be the same.
Extruder / Die Characteristics – Effect of process variables
For Other Die Geometries

For other geometries it is possible to use the empirical equation for obtaining the output

b is the greatest dimension of the cross-section


d is the least dimension of the cross-section
F is a non-dimensional factor

Using above relation, it is possible to modify the


expression for the operating pressure in general
form as
Example:
A single screw extruder is to be used to manufacture a nylon rod 5 mm in diameter at a production rate of 1.5 m/min. Using
the following information, calculate the required screw speed.

420

The solid is more dense than the melt. So, the melt flow rate must be greater in the ratio of the solid/melt densities.
Temperature Rise in Die
Work = (force) x (distance)

Power = (force) x (distance per unit time) = (Pressure drop x area) x (velocity)

But the volume flow rate, Q, is given by Q = area x velocity

Therefore, Power = P Q (where P is pressure drop, Q = volume flow rate)

Using this expression it is possible to make an approximation for the temperature rise of the fluid during extrusion through
a die. If it is assumed that all the energy is changed into shear heating and that all the heat is taken up evenly by the
polymer, then the energy may be equated to the temperature rise in the polymer.

Power = Heat required to change temperature = mass x specific heat x temperature rise

where p is the density of the fluid Cp is its specific heat


Granule Production / Compounding
• Extruder may be used to
convert polymer formulations
and additives into a form
(usually granules) which is
more convenient for use in
other processing methods, such
as injection moulding.

• In the extruder the feedstock is


melted, homogenised and
forced through a capillary
shaped die.

• It emerges as a continuous lace


which is cooled in a long water
bath so that it may be chopped
into short granules and packed
into sacks.
Profile Production

A simple operation
of a die change can
provide a wide range
of profiled shapes
such as pipes,
sheets, rods, frames,
etc.

The extrudate is
usually cooled in a
water bath, the length
of which depends on
the section and the
material being cooled.
Film Blowing
Blow Moulding
Extrusion Stretch Blow Moulding – Bi-axial stretching possible

Neck ring stretch blow moulding


Extrusion Coating Process
Extrusion Wire Coating
Co-Extrusion
Videos
https://www.youtube.com/watch?v=lh4edjYWzqg

https://www.youtube.com/watch?v=o_VPbYtdCnk

https://www.youtube.com/watch?v=u7r2neJ2Yfs

https://www.youtube.com/watch?v=uXH_gF3XCbU

https://www.youtube.com/watch?v=WaB-dsB1Kfk
Profile Extrusion
Blow film Extrusion
Thin film Extrusion
Large Pipe Extrusion
Pipes Extrusion

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