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Extrusion Molding Methods
Extrusion Molding Methods
Extrusion of plastics, like injection molding, is a relatively simple concept, but the design and application of extruders is a complex field
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There are two types of screw extruders, co-rotating and counter-rotating screw extruders
The screws in co-rotating extruders turn in the same direction The screws in counter rotating extruders turn in opposite directions
For either class of extruder, the flights may or may not be intermeshing
Intermeshing extruders work on a different principle than single screw extruders; material is pumped by forward action of the root of one screw against the flights of the other
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Counter rotating intermeshing extruders are the next most common type
Material in this case is moved as a unit volume between the screws and barrel Spacers, disk rings and other flow interrupters may be used to disrupt the characteristic encapsulated flow Higher material volumes may be extruded in this configuration This type of extruder evolved from pumping machines
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Die Swell
When polymer exits the die of the extruder it will swell, this action is referred to as die swell
Die swell occurs because the sudden release of pressure causes the polymer chains to relax; remember, polymers are viscoelastic and display time dependent stress relaxation Go to http://www.pct.edu/prep/ex.htm and click on the die swell animation to view a cartoon of the concept
sudden release of pressure is the main factor responsible for die swell; shear rate and pressure can be influenced by
Increasing the output rate Decreasing die orifice dimension Reducing the melt temperature Increasing molar mass (molecular weight), chain branching Decreasing the die L/D ratio
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Extrusion Shapes
For melt extrusion the extrusion machine will be similar for all cases, the die and application being differentiating facets The shape of the extruded section will depend on the die orifice shape (and die swell, of course); the type of shape produced is divided into several categories
Sheet (more than 0.25 mm thick) Film (less or equal to 0.25 mm thick) Blown, film casting, calendering Filament Blow molding Wire insulation
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Sheet Extrusion
ASTM has defined sheet as being more than 0.25 mm thick Sheet is extruded by cast extrusion, which simply refers to sheets being extruded through a horizontal die
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Film Extrusion
ASTM has defined film as being equal to or less than 0.25 mm in thickness Film can be extruded in a similar manner as sheet in a process referred to as slot casting
In this case, the film is drawn from the die onto chilled rollers that quickly quench the material
The blown film process extrudes a tube of material and pinches of the end while simultaneously blowing the tube into a thin walled balloon Click on the download button at http://www.glad.com.au/student_main.asp to get product propaganda but also some interesting info. on how Glad Wrap and garbage bags are made at Glad
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Blow Molding
The basic principle of blow molding is simple; a hollow molten preform or tube is placed in a female mold and inflated to conform to the shape of the mold
Two different varieties of blow molding Injection blow molding is a two step process where a blank preform is first molded, it is then transferred to the mold cavity where it is blown into shape The advantages of injection molding are good control of wall thickness, no bottom pinch off line, no scrap; the main disadvantage is requiring two molds and transfer time to the mold after performing Extrusion blow molding a molten tube (parison) is extruded, without pre-forming, the bottom of the parison is pinched of by the mold and air is used to blow it into shape The main disadvantage of this method is the less controllable wall thickness, though some basic control is possible
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The Plastics Resources for Educators Program. http://www.pct.edu/prep/core.htm - great descriptions and animations of processes. Review animations for extrusion and injection.
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