Polymer Processing Operation

“Sheet Extruding Machine”

Submitted to: Dr. Muhammad Sarfraz

Group # 6

Maliha Hanif 2019-PE-34

Andleeb Arshad 2019-PE-21

Zarqullah Javaid 2019-PE-11

Abdulrehman 2019-PE-27

DEPARTMENT OF POLYMER AND PROCESS ENGNEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY
LAHORE

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 Table of Contents
Objective:....................................................................................................................................................3
Abstract:......................................................................................................................................................3
1. Introduction:............................................................................................................................................3
2. Related Theory:.......................................................................................................................................3
3. Working Principle:..................................................................................................................................5
4. Safety Aspects:........................................................................................................................................6
5. Apparatus:...............................................................................................................................................6
6. Material Selection:...................................................................................................................................6
7. Procedure:................................................................................................................................................6
8. Results and Discussion:...........................................................................................................................7
9. Conclusive Remarks:...............................................................................................................................7
10. Questionnaires:......................................................................................................................................7
Explain the effect of stretching on thickness and uniformity on the product?.................................7

Discuss the effect of length of the cooling tank on product quality?.................................................8

References:..................................................................................................................................................9

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 Sheet Extruding Machine

Objective:
 To describe the process of sheet extrusion line.
 To understand the effects of process variables on the efficiency and properties of
products.

Abstract:
Sheet extrusion is best process for the production of article that have different type of thickness
but horizontally liner just like a cotton blanket. There is a very vast use of sheets in present era
due to industrial revolution. In this process, continue sheet is extruded from an extruder. Resin
added into hopper melts into barrel and then continuously extruded into a horizontal die that set
the thickness of the material. First, material melts then extruded into mold to form a long
continue sheet.

1. Introduction:

Sheet extrusion is a method for formation of flat plastic sheets from different type of resins that
are have different end application in market. It is a variation of this process in which continuous
sheets of plastic are extruded in different widths for vacuum forming and other secondary
production processing. Resin is melted and continuously extruded through a mold by a screw to
form a mold of product of different shapes and size for different application. Width of sheet can
be varying for different applications. Pipe and tubing extrusion are produced from similar die
designs, as the pipe exits the die, it is pulled through a cooling and sizing apparatus.

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2. Related Theory:

During the plastic extrusion process, a raw material made of a thermoplastic type in the form of
a small bead often called a resin in the industry is pulled by gravity from the top hopper mounted
in the extruder barrel. Additives such as colorants and UV inhibitors (either liquid or pellet form)
are commonly used and can be mixed with resin before reaching the hopper or added with a co
extruder.

Fig. 1 Show the barrel and screw system

Items enter through the feed throat which is opening near the back of the barrel and meet with a
screw. The rotating screw which usually rotates up to 120 rpm forces the plastic beads forward
into the barrel heated to the desired melting temperature of the molded plastic about 200 ° C to
325 ° C depending on the polymer.

Fig. 2 Extrusion of sheet through die

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In most cases, the temperature profile is set to the barrel where three or more self-controlled PID
components slowly heat the temperature of the rear drum (where plastic enters) the front. This
allows the plastic beads to melt slightly as they are pushed into the bin and reduce the risk of
overheating which can cause damage to the polymer.

3. Working Principle:

Working on sheet extruding machine is simple like extrusion machine. Barrel is heated up.
Temperature is adjusted across the three sections of the tube such as feed section metering
section. The last screw thread in the mouth of the feeder is called the transportation phase. Items
in this category cannot be placed in plastic, but required to be preheated and extruded. In the
past, the old theory of extrusion thought that the material in the first stage was free, but now by
showing that the material is solid, which means that the material looks like a solid plug after
squeezing. The second part of a single screw sheet extrusion machine is called a compress
section. The volume of the windshield varies from large to small, and at the same time the
temperature should reach the level of the plastic inserts with the material. Here the compression
of a mean that the screw compression ratio is 3: 1, but there are other distinct reduction values.
After that the plastic material goes to the third stage. The third part of a single screw sheet
extrusion machine is the counting phase. The contents here should retain heat made of plastic.
This section only requires the accuracy and measurement of nasal melting materials such as a
measuring pump.

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 Fig 3. Sheet extruding machine

4. Safety Aspects:

 Use heat resistant gloves in order to protect your hands

 Wear laboratory coat as protective equipment
 Use safety goggles in laboratory
 Wear mask to protect respiratory system

5. Apparatus:
 Sheet Extrusion molding machine:
 Cutting tools
 Vernier caliper
 Weight balance

6. Material Selection:
 Specific grade of HDPE for sheet extrusion

7. Procedure:
 Before starting the extrusion process, check all the parts and machine for safety purpose.
 Then, start machine by turning on the power supply button
 Adjust the temperature and all other important measurement that are important for the
production of the specific product.
 Depending upon the type of polymer or material used, set the temperature of the barrel
i.e. 110˚C to 240˚C. For HDPE, set the temperature almost 131℃
 Then allow the barrel to preheat for almost half an hour so that the temperature will be
uniform throughout the barrel.
 Insert the material in the hopper and start the machine.

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  Adjust the speed of the stretcher according to the desired thickness or width.
 Operate the extruder maximum till required amount of product.

8. Results and Discussion:

 Results are not available because of some technical fault in sheet extruding machine.

9. Conclusive Remarks:
Sheet Extrusion process is widely used in industrial working. It is much important in present
time because of massive of polymeric product, so its sheet quality matters. Sheet extrusion is just
like extrusion of all other type of extrusion only a small different of die. Extrusion like wire
coating, film extrusion etc. are same but having phenomena. In sheet extrusion, sheets are
extruded into horizontal channel of die and cooling network where we get our end product.

10. Questionnaires:

Explain the effect of stretching on thickness and uniformity on the product?

Stretching sets, the size or thickness of sheet. Non-uniform thickness in extruded sheet is a serious
problem. In the case of thin sheet for thermoforming, uniform gauge is critical to achieving proper wall
thickness in formed parts and to preventing optical distortion, both serious quality issues for packaging.
With heavy sheet, gauge variation brings the added problem of warpage, you often have to reheat the
sheet on rollers to get it flat. Many other problems also will be resulted. And at last, polymer is not
matched to the die design and uneven product can result.

Explain the effect of shear rate and winding speed on thickness of the sheet?

Shear rate and winding speed cause effect in the thickness of sheet, more the shear rate
and velocity thinner the sheet and vice versa.

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 Fig. 4 show the relation of shear rate and winding velocity

Discuss the effect of length of the cooling tank on product quality?

Fast cooling can affect the physical and chemical property of product. more low the cooling more
accuracy in the dimensions more shining produce. End product will be better end surface finish if cooling
tank is more long.

Effect of Split Die

Die lines could be caused by buildup or blockage in the die, or by damage to the flow
surfaces in the die. Die buildup can be cleaned away by running purge material while
varying extruder rpm, or it may be necessary to carry out a “split and clean” procedure.
But while cleaning is the likeliest solution to die lines, it may be that the propagation of
the buildup that caused the lines in the first place can be slowed down by increasing the
die-zone temperature set points. If an inspection of the flow surfaces indicates dents or
scratches, have the die professionally repolished and the lip edges resharpened.

Problems of Split die

 Grainy surface or “orange peel.”

 Rough surface or “shark skin.”
 Bubbles, pits, or dimples
 Wavy edges.
 High Shrinkage
 Dull or spotty surface

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References:
 Chanda, M., & Roy, S. K. (2006). Plastics technology handbook. CRC press.

 A.Brent strong, (2006), Plastic Materials and Processing, Pearson prentice hall, 393-395.

 Zaikov, G. E., Gumargalieva, K. Z., Pokholok, T. V., & Moiseev, Y. V. (1998). PVC
wire coatings: Part II characterizations and performance predictions. International
Journal of Polymeric Materials, 39(3-4), 261-288.