2.1 DIE DESIGN: One of the keys to successful profile extrusion is combining good profile cross sectional designs with good die design. Some companies specialize in computer-aided die designs based on computer modeling. With the desired profile cross section defined, the rheological parameters (viscosity versus shear rate, extension modulus and flow modulus) for the resin and the throughput rate, computer programs can design the die cross section required, while predicting the pressure drops, melt ‘temperature, and flow profiles within the die. The die has to be properly designed to have uniform flow and pressure drops in all the legs of the profile. Improperly designed dies can lead to severe warpage problems associated with the profiles. Higher polymer flow rates in one section of the die compared to another will result in different molecular orientation, This causes different shrinkage characteristics from one section to the other. Melt temperature in all channels needs to be similar to prevent one profile section from being hotter than another. Polymer melt pressure and flow in the various die sections can be kept constant through uniform wall thickness and proper design. Figure 2.3 shows some different cross sections with two different geometries, one being preferred over the other. Poor Designs = Figure 2.3 Comparison of profiles with uniform versus non-uniform cross sections, Depending on the profile, constant wall thickness over the entire part is not always possible. The resistance to flow in a die channel is given by Eq, (2.1). ap (2.1) axe Where, R= Resistance to flow AP = Pressure drop 7 = Melt viscosity Q= Volumetric throughput rate Since the volumetric throughput of the different channels has to be constant to prevent warpage, Q1= Q2 = 93 =... On. Ifthe melt temperature is the same and the shear rates are similar, the melt viscosity in the different channels will be the same. This leaves the pressure drop to balance the resistance in each section or leg of the die. The pressure drop is calculated from Eq. (2.2): 2xrxl ap = — Eq. (2.2) Where, ‘T= Shear stress = force/area l= Channel length h = Channel height 37If the cross sectional area of each output section or leg is the Sink same, the pressure drop in each leg will be identical, assuming the rest of the die has a uniform melt flow. Sink marks opposite ribs are eliminated with part design. Sink is Desired caused by shrinkage. Extruded profiles with thicker cross Profile wth Profile Sink sectional areas shrink more due to the higher mass than adjoining thinner areas. This creates an imperfection ‘opposite a rib that is readily visible. Figure 2.4 shows a Peek de ‘type profile and the corresponding sink mark. ‘Sink Eliminating the sink mark in the final part is accomplished by making the area opposite the rib slightly thicker, so with Figure 2.4 Effect of sink and die shrinkage it becomes the same thickness as the rest of the modification to eliminate sink. profi le. Extrudate swell, discussed previously in Part 1, is attributed to the clastic portion of the viscoclastie beha area, wior that makes the polymer want to spring back after the polymer exits the die, In the die land the polymer flow simulates the plug flow in a pipe, where the polymer velocity at the wall is zero. After the polymer exits the die, the velocity profile is the same at the surface as itis in the center. This, is shown in Fig. 2.5. Extrudate swell requires the die to be cut differently than the actual profile desired. A die to produce a square rod is shown in Fig. 2.6 versus a die cut with a square hole and the resulting profi le. Die fF Dio Sue \ Extruder > = | Figure 2.5 Die Swell as polymer exits die Figure 2.6 Die configuration to produce 2A a square profile. Design parameters: Proper die design is required to produce uniform parts at high rates without warpage. Design criteria include the following: 1. Thicker walls require more time for cooling, leading to lower production rate. Calculate the wall thickness required based on the product performance requirements. Ideal the wall thickness is approximately 0,03 to 0.12 inch (0.7 to 3mm ). Wall thickness can be reduced and still provide the same stiffness with the incorporation of ribs on the back side or the use of corrugated structures. Uneven wall thicknesses lead to uneven flow in the die and differential profile cooling that can lead to warpage, bow, and twist in the final part. If more than one wall thickness is present in the part, make the transition from one wall thickness to the next gradual. Ribs lead to sink marks caused by the extra mass and the polymer shrinkage. Eliminating sink marks can be accomplished by building the profile up opposite the rib or making the rib smaller so there is less material 58 All inner and outer comers need to be designed with proper radii, eliminating sharp corners. Sharp comers generate high stress areas that can cause premature part failure.6. Eliminate through-holes in the profile wherever possible; these are expensive from both a tooling perspective and the potential need for vacuum sizing. It is better to have throughholes in a profile than uneven wall thicknesses. Uneven walls can lead to more significant processing problems 2.1.2 Land Length & Draw down ratio: Key factors in die design are the land length and the draw down ratio. 2.1.2.1 Land Length: The land length is defined as the uniform flow channel just prior to the die exit. The land lengths within the die determine the flow resistance for the different profile sections or channels. Thinner profile sections require less land length than thicker sections in the profile to produce the same flow resistance. Longer land lengths are used to produce profiles with higher gloss. The proper land length depends on the die gap, the orifice area, flow rates, melt viscosity, and the optimum pressure for the die and extruder. ——____—_— 2.1.2.2 Draw Down: Material | Die Land Length | Draw Down, % Draw down ratio is the draw between the die] _ LDPE 15:1 30 and the final shape. As polymer exits the die, it is drawn by the puller and shaped by a MDPE 15:1 25 sizing device to produce the desired shape. The draw determines the final molecular HDPE 15:1 20 orientation in the part and the product PP 15:1 30 performance. 525 Die land lengths and draw down ratio are PPVC 15:1 " recommended by resin manufacturers, and GPs 20:1 8-20 some guidelines are provided in Table 2.1 - ABS 25:1 25 Nylon 6,6 20:1 15-20 Nylon 6 20:1 20 PC 10:1 15-25 93 EXTRUDER T GHPUT CALCULATIONS: Extruder output is equal to the volumetric drag flow rate minus the pressure flow rate minus any leakage flow. Fq.(9.3) Where, @= Qo ~ Qr— OQ Q= Plastic Output Qp= Drag Flow Qp= Pressure Flow Qi=Leakage Flow 9.3.1 Volumetric drag flow: WHY Atm , | x HS) Eq.(9.4) 59 Vz = nDN cos@Where, W = channel width H = channel depth V, = plastic velocity in channel D = screw diameter (large) N = screw speed in RPM @= helix angle N= power law index 9.3.2 Pressure flow: Where, WH? sind AP) 3 >. ee (ae Eq.(9.5) ‘W= channel width 1 plastic viscosity at given shear rate H= channel depth 4E= pressure change in metering section of length L = helix angle n= power law index va tam | Pain | 25 | pensey | Thermal |. Speifi Material | tagex | (tm) | Transition | OUT | conductivity | Heat Cp( a (Tg) °c k(J/imsC) | kj/kg C) (n) c PS 03 5 Tor 1.06 O12 12 Pvc [03 : 80 14 0.21 Ld PMMA _| 0.25 : 105 1.18 02 1.45 SAN | 03 : 115 1.08 0.12 14 ABS | 0.25 : 115 1.02 0.25 14 pc | 07 : 150 12 0.19 14 LDPE [0.35 _[ 120 =120 0.92 0.24 23 LLDPE [0.6 _|__125 =120 0.92 0.24 23 HDPE | 05 | 130 =120 0.95 0.25 2.25 pp__| 0.3a5_| 175 =10 0.91 0.15 PAG [07 _|_225 30 113 0.25 PA66 [0.75 [265 55 114 0.24 PET | 0.6 | _275 70 1.35 0.29 PBT | 0.6 | 250 45 1.35 0.21 ‘Table 9.1 lists various polymer properties. 60