Shaping Processes For Plastics - Extrusion

1. Introduction

Extrusion is a compression process in which

the material is forced to flow through a die
orifice to provide long, continuous product
whose cross-sectional shape is determined by
the shape of the orifice
Handouts 4b

Shaping Processes For Plastics - Extrusion

1. Introduction

Screen pack

Handouts 4b

Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate

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What are questions about the extrusion?

1. Flow rate (volume) inside the extruder ?
2. Flow rate (volume) through the die ?

die

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Find the
Relationship of
these two

Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate
Drag flow

Screw surface

d
Barrel

Handouts 4b

Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate

Qd 0.5vdw

dc

v DN cos A

wc (D tan A w f ) cos A

Qd 0.5 D Nd c sin A cos A

2

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(1)
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Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate

Back pressure flow

Dd sin A dp
Qb
( )
12
dl
3
c

pDd sin A
Qb
12L
3
c

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(2)

Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate
Net forward flow Qx

pDd sin A
Qx 0.5 D Nd c sin A cos A
12L
2

3
c

(3)

Two categories of parameters:

design parameter and operating parameter

Handouts 4b

Shaping Processes For Plastics - Extrusion

The design parameters: those that define the geometry
of the screw and barrel.
The operating parameter: those that can be changed
during the process to affect the output flow
3
2
p

Dd
sin
A
2 2
c
Qx 0.5 D Nd c sin A cos A
12L

Handouts 4b

Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate
Maximum pressure and maximum net flow rate

Qmax

pDd sin A
0.5 D Nd c sin A cos A
12L
2

3
c

Maximum head pressure to cause no flow

pmax

6DNL cot A

2
dc
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Shaping Processes For Plastics - Extrusion

2. Analysis of Flow Rate

Extruder characteristic
Qmax

pmax

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Shaping Processes For Plastics - Extrusion

3. Determination of the operating point
Pressure and Flow rate

Qx K s p
D
Ks
128Ld

die

4
d

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Die characteristic
12

Shaping Processes For Plastics - Extrusion

3. Determination of the operating point
Qx

Die characteristic
Qmax

Operating point
Extruder characteristic
pmax
p
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Example:
Given: diameter D=120 mm
length =3.0 m
channel depth =8.0 mm
pitch = 95 mm
viscosity = 75 pas
heat pressure = 4.0 Mpa
Find: the rotational speed of the screw required to
achieve a volumetric flow rate of 90 cm3/s
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