Extrusion
Extrusion
Extrusion
Overview
The pasty molten material is then sent to the metering zone, where it
acquires a constant flow rate, imparted by the helical flight of the
screw.
The pressure build-up in this section enables the polymer melt to
enter the die and emerge out of it with the desired profile.
Process Description…
• Due to high viscous nature of some polymers, however, one
more region called the working zone may also be required
wherein the polymer could be subjected to high shearing forces
for effective mixing.
• Cold air blast and cold water spray can be used for cooling.
Twin screw
co-rotating, counter rotating
Extrusion Screw
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Extrusion Screw…
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Extrusion Screw…
Extrusion Screw…
Screws for various processes
Melting stages
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Screw Wear
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Extrusion Die
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Extrusion Die…
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Extrusion Die…
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Critical operation parameters
• Melt temperature
• Melt pressure
• Barrel temperature
• Die temperature
• Heater power
• Screw speed
• Line speed
• Finished products dimension
• Cooling rate
Extrusion problems
• Melt fracture
• Sharkskin or alligator hide
• Uneven flow and surging
• Degradation
• Poor mixing
• Contamination
• Bubbles in extrudate
Sharkskin or alligator hide
> Bambooing occurs when the outer edge material snaps back
to relive stresses
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Materials consideration
• Most thermoplastics
• Extrusion grade
• High MW, low MFI <1
• Broad MWD
• Melt strength
• Some materials (like PVC) need lubricant
• Density differences can cause problems
like Fiber breaking
Applications
• Compounding
• Profile
• A number of extrusion
based processes
Application : Extrusion process
Profile
Pipe & tubing
Wire coating
Sheet & flat film
Blown film
Coating
Calendaring
Fiber spinning
Co extrusion, …