Wikipedia Plastics extrusion

From Wikipedia, the free encyclopedia

This article needs additional citations for verification. Please help improve this article by adding citations to reliable sources. Unsourced material may be challenged and removed. (October 2009)

Cross-section of a plastic extruder to show the screw

Plastics extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weather stripping, fence, deck railing, window frames,plastic films, themoplastic coatings, and wire insulation.
Contents
[hide]

1 History 2 Process 3 Screw design 4 Geometrical possibilities 5 Typical extrusion materials 6 Extrusion Method 7 Features 8 Types

o o

8.1 Sheet/film extrusion 8.2 Blown film extrusion

o o o o o

8.3 Overjacketing extrusion 8.4 Tubing extrusion 8.5 Coextrusion 8.6 Extrusion coating 8.7 Compound extrusions

9 See also 10 References

10.1 Bibliography

[edit]History
The first thermoplastic extrusion was in 1935 by Paul Troester in Germany. Shortly after, Roberto Colombo of LMP developed the first twin screw extruders in Italy.[1]

[edit]Process
In the extrusion of plastics, raw thermoplastic material in the form of small beads (often called resin in the industry) is gravity fed from a top mounted hopper into the barrel of the extruder. Additives such as colorants and UV inhibitors (in either liquid or pellet form) are often used and can be mixed into the resin prior to arriving at the hopper. The process has much in common withplastic injection moulding from the point of the extruder technology though it differs in that it is usually a continuous process. While pultrusion can offer many similar profiles in continuous lengths, usually with added reinforcing, this is achieved by pulling the finished product out of a die instead of extruding the fluid raw material through a die. The material enters through the feed throat (an opening near the rear of the barrel) and comes into contact with the screw. The rotating screw (normally turning at up to 120 rpm) forces the plastic beads forward into the barrel which is heated to the desired melt temperature of the molten plastic (which can range from 200 C (392 F) to 275 C (527 F) depending on the polymer). In most processes, a heating profile is set for the barrel in which three or more independent PID controlled heater zones gradually increase the temperature of the barrel from the rear (where the plastic enters) to the front. This allows the plastic beads to melt gradually as they are pushed through the barrel and lowers the risk of overheating which may cause degradation in the polymer. Extra heat is contributed by the intense pressure and friction taking place inside the barrel. In fact, if an extrusion line is running certain materials fast enough, the heaters can be shut off and the melt temperature maintained by pressure and friction alone inside the barrel. In most extruders, cooling fans are present to keep the temperature below a set value if too much heat is generated. If forced air cooling proves insufficient then cast-in heater jackets are employed, and they generally use a closed loop of distilled water in heat exchange with tower or city water.

Plastic extruder cut in half to show the components

At the front of the barrel, the molten plastic leaves the screw and travels through a screen pack to remove any contaminants in the melt. The screens are reinforced by a breaker plate (a thick metal puck with many holes drilled through it) since the pressure at this point can exceed 5000 psi (34 MPa). The screen pack/breaker plate assembly also serves to create back pressure in the barrel. Back pressure is required for uniform melting and proper mixing of the polymer, and how much pressure is generated can be 'tweaked' by varying screen pack composition (the number of screens, their wire weave size, and other parameters). This breaker plate and screen pack combination also does the function of converting "rotational memory" of the molten plastic into "longitudinal memory". After passing through the breaker plate molten plastic enters the die. The die is what gives the final product its profile and must be designed so that the molten plastic evenly flows from a cylindrical profile, to the product's profile shape. Uneven flow at this stage would produce a product with unwanted stresses at certain points in the profile. These stresses can cause warping upon cooling. Almost any shape imaginable can be created so long as it is a continuous profile. The product must now be cooled and this is usually achieved by pulling the extrudate through a water bath. Plastics are very good thermal insulators and are therefore difficult to cool quickly. Compared with steel, plastic conducts its heat away 2000 times more slowly. In a tube or pipe extrusion line, a sealed water bath is acted upon by a carefully controlled vacuum to keep the newly formed and still molten tube or pipe from collapsing. For products such as plastic sheeting, the cooling is achieved by pulling through a set of cooling rolls. Sometimes on the same line a secondary process may occur before the product has finished its run. In the manufacture of adhesive tape, a second extruder melts adhesive and applies this to the plastic sheet while its still hot. Once the product has cooled, it can be spooled, or cut into lengths for later use.

Plastic extruders are also extensively used to prepare recycled plastic waste and/or raw materials after cleaning, sorting and/or blending into filaments suitable for chopping into the 'resin' bead or pellet stock used by the plastics industry at large.

[edit]Screw

design

There are five possible zones in a thermoplastic screw. Since terminology is not standardized in the industry, different names may refer to these zones. Different types of polymer will have differing screw designs, some not incorporating all of the possible zones.

A simple plastic extrusion screw

Most screws have these three zones:

Feed zone. Also called solids conveying. This zone feeds the resin into the extruder, and the channel depth is usually the same throughout the zone.

Melting zone. Also called the transition or compression zone. Most of the resin is melted in this section, and the channel depth gets progressively smaller.

Metering zone. Also called melt conveying. This zone, in which channel depth is again the same throughout the zone, melts the last particles and mixes to a uniform temperature and composition.

In addition, a vented (two-stage) screw will have:

Decompression zone. In this zone, about two-thirds down the screw, the channel suddenly gets deeper, which relieves the pressure and allows any trapped gases (usually moisture or air) to be drawn out by vacuum.

Second metering zone. This zone is like the first metering zone, but with greater channel depth, and repressurizes the melt to get it through the resistance of the screens and the die.

Often screw length is referenced to its diameter as L:D ratio. For instance, a 6-inch (150 mm) diameter screw at 24:1 will be 144 inches (12 ft) long, and at 32:1 it is 192 inches (16 ft) long. An L:D ratio of 24:1 is common, but some machines go up to 32:1 for more mixing and more output at the same screw diameter. Two-stage (vented) screws are typically 36:1 to account for the two extra zones. Each zone is equipped with one or more thermocouples or RTDs in the barrel wall for temperature control.

[edit]Geometrical

possibilities

There are many geometrical possibilities when using extrusion. Thin film (flat or tubular) is the most common product. Other extruded products include pipe and tubing, coated paper or foil, monofilaments and

textile fibers, flat sheet (anything over 0.010 inch (0.25 mm)), wire and cable covering, and a great variety of profiles such as window frames, gaskets and channels, and house siding. The products can be cut to length or rolled up as needed.[2]

[edit]Typical

extrusion materials

Typical plastic materials that are used in extrusion include but are not limited to: polyethylene (PE), polypropylene, acetal, acrylic, nylon (polyamides), polystyrene, polyvinyl chloride (PVC),acrylonitrile butadiene styrene (ABS) and polycarbonate.[2]

[edit]Extrusion

Method

By plasticizing way, there are dry extrusion and wet extrusion. By pressurizing way, there are continuous extrusion and intermittent extrusion.

[edit]Features
Continuous production, high efficiency, simple operation, a wide range of applications, such as tubing extrusion, sheet/film extrusion etc.[3]

[edit]Types [edit]Sheet/film

extrusion

Blow extrusion of plastic film

For products such as plastic sheet or film, the cooling is achieved by pulling through a set of cooling rolls (calender or "chill" rolls), usually 3 or 4 in number. Running too fast creates an undesirable condition called "nerve"- basically, inadequate contact time is allowed to dissipate the heat present in the extruded plastic. In sheet extrusion, these rolls not only deliver the necessary cooling but also determine sheet thickness and surface texture (in case of structured rolls; i.e. smooth, levant, haircell, etc.).

Often co-extrusion is used to apply one or more layers on top of a base material to obtain specific properties such as UV-absorption, soft touch or "grip", matte surface, or energy reflection, where it is needed : on the surface. A common post-extrusion process for plastic sheet stock is thermoforming, where the sheet is heated until soft (plastic), and formed via a mold into a new shape. When vacuum is used, this is often described as vacuum forming. Orientation (i.e. ability/ available density of the sheet to be drawn to the mold which can vary in depths from 1 to 36 inches typically) is highly important and greatly affects forming cycle times for most plastics. Thermoforming can go from line bended pieces (e.g. displays) to complex shapes (computer housings), which often look like they have been injection moulded, thanks to the various possibilities in thermoforming, such as inserts, undercuts, divided moulds. Plastic extrusion onto paper is the basis of the liquid packaging industry (juice cartons, wine boxes...); usually an aluminum layer is present as well. Infood packaging plastic film is sometimes metallised, see metallised film.

[edit]Blown

film extrusion

The manufacture of plastic film for products such as shopping bags and continuous sheeting is achieved using a blown film line.[4] This process is the same as a regular extrusion process up until the die. The die is an upright cylinder with an annular opening similar to a pipe extrusion die.[5] The opening diameter can be a few centimetres to more than three metres across. The molten plastic is pulled upwards from the die by a pair of nip rolls high above the die (4 metres to 20 metres or more depending on the amount of cooling required). Changing the speed of these nip rollers will change the gauge (wall thickness) of the film. Around the die sits a cooling ring that blows air onto the film tube as it travels past. The air flow cools the film as it travels upwards. In the centre of the die is an air outlet trough which compressed air can be forced into the inside of the extruded cylindrical profile, adjusting the bubble volume. This expands the extruded circular cross section by some ratio (a multiple of the die diameter). This ratio, called the blowup ratio can be below unity to 8 and indicates how the bubble diameter compares to the die diameter. The nip rolls flatten the bubble into a double layer of film whose width (layflat) is equal to half the circumference of the bubble. This film can then be slit, spooled, printed on or cut into shapes and heat sealed into bags or other items. An advantage of blown film extrusion over traditional film extrusion is that in the latter there are edges where there can be quality (thickness) variations. Blown film extruders require limited amounts of compressed air for two operations: 1) To increase the film width by adding air inside the bubble. Once the bubble is inflated, no additional air is required. The air is trapped inside, and with the help of the top nip rolls and cooling air, shapes the plastic tube to the desired width and film thickness. The volume of air required initially depends highly on the size

of the machine and width to be extruded. This can be anywhere from 50l to 400l of uncompressed air. As this is only required at the start of a production run, flow rate is to be considered as insignificant. A compressor with a tank size of about 200l at a working pressure of 8 Bar can store more than 1000l of uncompressed air. 2) To apply pressure on the nip rolls, these need to be held together so that the film can be pulled up. It is important that even and regulated pressure is used to ensure proper thickness control. The pressure required can be adjusted by an air pressure regulator attached to the machine. The incoming pressure needs to be more than 6 Bar. Ideally a compressor, with more than 8 Bar but less than 11 Bar, is used in conjunction with a regulator to maintain the pressure. As the application is only to apply pressure, any air loss is only through leakage. As per ISO standards, 0.1l/connection/hr is the maximum allowable leakage for pneumatics. There are about 36 connections in an average blown film extruder. So a leakage rate of 3.6l/hour (0.06l/min) could be expected. This is also very low for any industrial compressor.

[edit]Overjacketing

extrusion

In a wire coating process, bare wire (or bundles of jacketed wires, filaments, etc.) is pulled through the center of a die similar to a tubing die. Many different materials are used for this purpose depending on the application. Essentially, an insulated wire is a thin walled tube which has been formed around a bare wire. There are two different types of extrusion tooling used for coating over a wire. They are referred to as either "pressure" or "jacketing" tooling. The selection criteria for choosing which type of tooling to use is based on whether the particular application requires intimate contact or adhesion of the polymer to the wire or not. If intimate contact or adhesion is required, pressure tooling is used. If it is not desired, jacketing tooling is chosen. The main difference in jacketing and pressure tooling is the position of the pin with respect to the die. For jacketing tooling, the pin will extend all the way flush with the die. When the bare wire is fed through the pin, it does not come in direct contact with the molten polymer until it leaves the die. For pressure tooling, the end of the pin is retracted inside the crosshead, where it comes in contact with the polymer at a much higher pressure.

[edit]Tubing

extrusion

Extruded tubing process, such as drinking straws and medical tubing, is manufactured the same as a regular extrusion process up until the die. Hollow sections are usually extruded by placing a pin or mandrel inside of the die, and in most cases positive pressure is applied to the internal cavities through the pin. Tubing with multiple lumens (holes) must be made for specialty applications. For these applications, the tooling is made by placing more than one pin in the center of the die, to produce the number of lumens necessary. In most cases, these pins are supplied with air pressure from different sources. In this way, the individual lumen sizes can be adjusted by adjusting the pressure to the individual pins.

[edit]Coextrusion

Coextrusion is the extrusion of multiple layers of material simultaneously. This type of extrusion utilizes two or more extruders to melt and deliver a steady volumetric throughput of different viscous plastics to a single extrusion head (die) which will extrude the materials in the desired form. This technology is used on any of the processes described above (blown film, overjacketing, tubing, sheet). The layer thicknesses are controlled by the relative speeds and sizes of the individual extruders delivering the materials. There are a variety of reasons a manufacturer may choose coextrusion over single layer extrusion. One example is in the vinyl fencing industry, where coextrusion is used to tailor the layers based on whether they are exposed to the weather or not. Usually a thin layer of compound that contains expensive weather resistant additives are extruded on the outside while the inside has an additive package that is more suited for impact resistance and structural performance.

[edit]Extrusion

coating

Extrusion coating is using a blown or cast film process to coat an additional layer onto an existing rollstock of paper, foil or film. For example, this process can be used to improve the characteristics of paper by coating it with polyethylene to make it more resistant to water. The extruded layer can also be used as an adhesive to bring two other materials together. A famous product that uses this technology is tetrapak.

[edit]Compound

extrusions

Compounding extrusion is a process that mixes one or more polymers with additives to give plastic compounds. The feeds may be pellets, powder and/or liquids, but the product is usually in pellet form, to be used in other plastic-forming processes such as extrusion and injection molding. Machine size varies from tiny lab machines to the biggest extruders in the industry, running as much as 20 tons per hour, as used by the chemical companies that make the base resins. Usually twin-screw extruders are preferred because they give better mixing at lower melt temperatures. Most of these have screws and barrels made up of smaller segments (mixing, conveying, venting and additive feeding) so that the design can be changed to meet the production and product needs. Single-screw extruders can be used for compounding as well, especially with appropriate screw design and static mixers after the screw. Selection of the components to be mixed (viscosities, additive carriers) is as important as the equipment.
[6][7]

Extrusion
From Wikipedia, the free encyclopedia

For the process that creates volcanic rock, see Extrusive (geology).

Extruded aluminium with several hollow cavities; slots allow bars to be joined with special connectors.

Extrusion is a process used to create objects of a fixed, cross-sectional profile. A material is pushed or drawn through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections and work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms finished parts with an excellent surface finish.[1] Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). The extrusion process can be done with the material hot or cold. Commonly extruded materials include metals, polymers, ceramics, concrete and foodstuffs. Hollow cavities within extruded material cannot be produced using a simple flat extrusion die, because there would be no way to support the center barrier of the die. Instead, the die assumes the shape of a block with depth, beginning first with a shape profile that supports the center section. The die shape then internally changes along its length into the final shape, with the suspended center pieces supported from the back of the die.
Contents
[hide]

1 History 2 Process

o o o o

2.1 Hot extrusion 2.2 Cold extrusion 2.3 Warm extrusion 2.4 Equipment

2.4.1 Forming internal cavities 2.4.2 Direct extrusion

2.4.3 Indirect extrusion 2.4.4 Hydrostatic extrusion 2.4.5 Drives

2.5 Extrusion defects

3 Materials

o o o o o o

3.1 Metal 3.2 Plastic 3.3 Ceramic 3.4 Food 3.5 Drug carriers 3.6 Biomass briquettes

4 Design 5 See also 6 References

o o

6.1 Notes 6.2 Bibliography

7 External links

[edit]History
In 1797, Joseph Brahma patented the first extrusion process for making lead pipe. It involved preheating the metal and then forcing it through a die via a hand driven plunger. The process wasn't developed until 1820 when Thomas Burr constructed the first hydraulic powered press. At this time the process was called squirting. In 1894, Alexander Dick expanded the extrusion process to copper and brass alloys.[2]

[edit]Process

Extrusion of a round blank through a die.

The process begins by heating the stock material (for hot or warm extrusion). It is then loaded into the container in the press. A dummy block is placed behind it where the ram then presses on the material to push it out of the die. Afterward the extrusion is stretched in order to straighten it. If better properties are required then it may be heat treated or cold worked.[2] The extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts.

[edit]Hot

extrusion

Hot extrusion is a hot working process, which means it is done above the material's recrystallization temperature to keep the material from work hardening and to make it easier to push the material through the die. Most hot extrusions are done on horizontal hydraulic presses that range from 230 to 11,000 metric tons (250 to 12,000 short tons). Pressures range from 30 to 700 MPa (4,400 to 100,000 psi), therefore lubrication is required, which can be oil or graphite for lower temperature extrusions, or glass powder for higher temperature extrusions. The biggest disadvantage of this process is its cost for machinery and its upkeep.[1]

Hot extrusion temperature for various metals

[1]

Material

Temperature [C (F)]

Magnesium

350-450 (650-850)

Aluminium

350-500 (650-900)

Copper

600-1100 (1200-2000)

Steel

1200-1300 (22002400)

Titanium

700-1200 (1300-2100)

Nickel

1000-1200 (19002200)

Refractory alloys

up to 2000 (4000)

The extrusion process is generally economical when producing between several kilograms (pounds) and many tons, depending on the material being extruded. There is a crossover point where roll forming becomes more economical. For instance, some steels become more economical to roll if producing more than 20,000 kg (50,000 lb).[2]

Aluminium hot extrusion die

Front side of a four family die. For reference, the die is 228 mm (9.0 in) in diameter.

Close up of the shape cut into the die. Notice that the walls are drafted and that the back wall thickness varies.

Back side of die. The wall thickness of the extrusion is 3 mm (0.12 in).

[edit]Cold

extrusion

Cold extrusion is done at room temperature or near room temperature. The advantages of this over hot extrusion are the lack of oxidation, higher strength due to cold working, closer tolerances, good surface finish, and fast extrusion speeds if the material is subject to hot shortness.[1] Materials that are commonly cold extruded include: lead, tin, aluminum, copper, zirconium, titanium, molybdenum, beryllium, vanadium, niobium, and steel. Examples of products produced by this process are: collapsible tubes, fire extinguisher cases, shock absorber cylinders and gear blanks.

[edit]Warm

extrusion

Warm extrusion is done above room temperature, but below the recrystallization temperature of the material the temperatures ranges from 800 to 1800 F (424 to 975 C). It is usually used to achieve the proper balance of required forces, ductility and final extrusion properties.[3]

[edit]Equipment

A horizontal hydraulic press for hot aluminum extrusion (loose dies and scrap visible in foreground)

There are many different variations of extrusion equipment. They vary by four major characteristics:[1] 1. Movement of the extrusion with relation to the ram. If the die is held stationary and the ram moves towards it then its called "direct extrusion". If the ram is held stationary and the die moves towards the ram its called "indirect extrusion".

2. The position of the press, either vertical or horizontal. 3. The type of drive, either hydraulic or mechanical. 4. The type of load applied, either conventional (variable) or hydrostatic. A single or twin screw auger, powered by an electric motor, or a ram, driven by hydraulic pressure (often used for steel and titanium alloys), oil pressure (for aluminum), or in other specialized processes such as rollers inside a perforated drum for the production of many simultaneous streams of material. Typical extrusion presses cost more than $100,000, whereas dies can cost up to $2000.

[edit]Forming internal cavities

Two-piece aluminum extrusion die set (parts shown separated.) The male part (at right) is for forming the internal cavity in the resulting round tube extrusion.

There are several methods for forming internal cavities in extrusions. One way is to use a hollow billet and then use a fixed or floating mandrel. A fixed mandrel, also known as a German type, means it is integrated into the dummy block and stem. A floating mandrel, also known as a French type, floats in slots in the dummy block and aligns itself in the die when extruding. If a solid billet is used as the feed material then it must first be pierced by the mandrel before extruding through the die. A special press is used in order to control the mandrel independently from the ram.[1] The solid billet could also be used with a spider die, porthole die or bridge die. All of these types of dies incorporate the mandrel in the die and have "legs" that hold the mandrel in place. During extrusion the metal divides and flows around the legs, leaving weld lines in the final product.[4]

[edit]Direct extrusion

Plot of forces required by various extrusion processes.

Direct extrusion, also known as forward extrusion, is the most common extrusion process. It works by placing the billet in a heavy walled container. The billet is pushed through the die by a ram or screw. There is a reusable dummy block between the ram and the billet to keep them separated. The major disadvantage of this process is that the force required to extrude the billet is greater than that needed in the indirect extrusion process because of the frictional forces introduced by the need for the billet to travel the entire length of the container. Because of this the greatest force required is at the beginning of process and slowly decreases as the billet is used up. At the end of the billet the force greatly increases because the billet is thin and the material must flow radially to exit the die. The end of the billet (called the butt end) is not used for this reason.[5]

[edit]Indirect extrusion
In indirect extrusion, also known as backwards extrusion, the billet and container move together while the die is stationary. The die is held in place by a "stem" which has to be longer than the container length. The maximum length of the extrusion is ultimately dictated by the column strength of the stem. Because the billet moves with the container the frictional forces are eliminated. This leads to the following advantages:[6]

A 25 to 30% reduction of friction, which allows for extruding larger billets, increasing speed, and an increased ability to extrude smaller cross-sections

There is less of a tendency for extrusions to crack because there is no heat formed from friction The container liner will last longer due to less wear The billet is used more uniformly so extrusion defects and coarse grained peripherals zones are less likely.

The disadvantages are:[6]

Impurities and defects on the surface of the billet affect the surface of the extrusion. These defects ruin the piece if it needs to be anodized or the aesthetics are important. In order to get around this the billets may be wire brushed, machined or chemically cleaned before being used.

This process isn't as versatile as direct extrusions because the cross-sectional area is limited by the maximum size of the stem.

[edit]Hydrostatic extrusion
In the hydrostatic extrusion process the billet is completely surrounded by a pressurized liquid, except where the billet contacts the die. This process can be done hot, warm, or cold, however the temperature is limited by the stability of the fluid used. The process must be carried out in a sealed cylinder to contain the hydrostatic medium. The fluid can be pressurized two ways:[6] 1. Constant-rate extrusion: A ram or plunger is used to pressurize the fluid inside the container. 2. Constant-pressure extrusion: A pump is used, possibly with a pressure intensifier, to pressurize the fluid, which is then pumped to the container. The advantages of this process include:[6]

No friction between the container and the billet reduces force requirements. This ultimately allows for faster speeds, higher reduction ratios, and lower billet temperatures.

Usually the ductility of the material increases when high pressures are applied. An even flow of material. Large billets and large cross-sections can be extruded. No billet residue is left on the container walls.

The disadvantages are:[6]

The billets must be prepared by tapering one end to match the die entry angle. This is needed to form a seal at the beginning of the cycle. Usually the entire billet needs to be machined to remove any surface defects.

Containing the fluid under high pressures can be difficult.

[edit]Drives
Most modern direct or indirect extrusion presses are hydraulically driven, but there are some small mechanical presses still used. Of the hydraulic presses there are two types: direct-drive oil presses and accumulator water drives. Direct-drive oil presses are the most common because they are reliable and robust. They can deliver over 35 MPa (5000 psi). They supply a constant pressure throughout the whole billet. The disadvantage is that they are slow, between 50 and 200 mm/s (28 ips).[7] Accumulator water drives are more expensive and larger than direct-drive oil presses, and they lose about 10% of their pressure over the stroke, but they are much faster, up to 380 mm/s (15 ips). Because of this

they are used when extruding steel. They are also used on materials that must be heated to very hot temperatures for safety reasons.[7] Hydrostatic extrusion presses usually use castor oil at pressure up to 1400 MPa (200 ksi). Castor oil is used because it has good lubricity and high pressure properties.[8]

[edit]Extrusion

defects

Surface cracking - When the surface of an extrusion splits. This is often caused by the extrusion temperature, friction, or speed being too high. It can also happen at lower temperatures if the extruded product temporarily sticks to the die.

Pipe - A flow pattern that draws the surface oxides and impurities to the center of the product. Such a pattern is often caused by high friction or cooling of the outer regions of the billet.

Internal cracking - When the center of the extrusion develops cracks or voids. These cracks are attributed to a state of hydrostatic tensile stress at the centerline in the deformation zone in the die. (A similar situation to the necked region in a tensile stress specimen)

Surface lines - When there are lines visible on the surface of the extruded profile. This depends heavily on the quality of the die production and how well the die is maintained, as some residues of the material extruded can stick to the die surface and produce the embossed lines.

[edit]Materials [edit]Metal
Metals that are commonly extruded include:[9]

Aluminium is the most commonly extruded material. Aluminium can be hot or cold extruded. If it is hot extruded it is heated to 575 to 1100 F (300 to 600 C). Examples of products includeprofiles for tracks, frames, rails, mullions, and heat sinks.

Brass is used to extrude corrosion free rods, automobile parts, pipe fittings, engineering parts. Copper (1100 to 1825 F (600 to 1000 C)) pipe, wire, rods, bars, tubes, and welding electrodes. Often more than 100 ksi (690 MPa) is required to extrude copper.

Lead and tin (maximum 575 F (300 C)) pipes, wire, tubes, and cable sheathing. Molten lead may also be used in place of billets on vertical extrusion presses.

Magnesium (575 to 1100 F (300 to 600 C)) aircraft parts and nuclear industry parts. Magnesium is about as extrudable as aluminum.

Zinc (400 to 650 F (200 to 350 C)) rods, bar, tubes, hardware components, fitting, and handrails. Steel (1825 to 2375 F (1000 to 1300 C)) rods and tracks. Usually plain carbon steel is extruded, but alloy steel and stainless steel can also be extruded.

Titanium (1100 to 1825 F (600 to 1000 C)) aircraft components including seat tracks, engine rings, and other structural parts.

Magnesium and aluminium alloys usually have a 0.75 m (30 in) RMS or better surface finish. Titanium and steel can achieve a 3 micrometres (120 in) RMS.[1] In 1950, Ugine Sjournet, of France, invented a process which uses glass as a lubricant for extruding steel.[10] The Ugine-Sejournet, or Sejournet, process is now used for other materials that have melting temperatures higher than steel or that require a narrow range of temperatures to extrude. The process starts by heating the materials to the extruding temperature and then rolling it in glass powder. The glass melts and forms a thin film, 20 to 30 mils (0.5 to 0.75 mm), in order to separate it from chamber walls and allow it to act as a lubricant. A thick solid glass ring that is 0.25 to 0.75 in (6 to 18 mm) thick is placed in the chamber on the die to lubricate the extrusion as it is forced through the die. A second advantage of this glass ring is its ability to insulate the heat of the billet from the die. The extrusion will have a 1 mil thick layer of glass, which can be easily removed once it cools.[3] Another breakthrough in lubrication is the use of phosphate coatings. With this process, in conjunction with glass lubrication, steel can be cold extruded. The phosphate coat absorbs the liquid glass to offer even better lubricating properties.[3]

[edit]Plastic

Sectional view of a plastic extruder showing the components

Main article: Plastics extrusion Plastics extrusion commonly uses plastic chips or pellets, which are usually dried in a hopper before going to the feed screw. The polymer resin is heated to molten state by a combination of heating elements and shear heating from the extrusion screw. The screw forces the resin through a die, forming the resin into the desired shape. The extrudate is cooled and solidified as it is pulled through the die or water tank. In some cases (such as fibre-reinforced tubes) the extrudate is pulled through a very long die, in a process called pultrusion. A multitude of polymers are used in the production of plastic tubing, pipes, rods, rails, seals, and sheets or films.

[edit]Ceramic
Ceramic can also be formed into shapes via extrusion. Terracotta extrusion is used to produce pipes. Many modern bricks are also manufactured using a brick extrusion process.[11]

[edit]Food
Main article: Food extrusion

Macaroni is an extruded hollow pasta.

Extrusion has application in food processing. Products such as certain pastas, many breakfast cereals, premade cookie dough, some french fries, certain baby foods, dry or semi-moist pet food and ready-to-eat snacks are mostly manufactured by extrusion. It is also used to modify starch and to pellet animal feed. In the extrusion process, raw materials are first ground to the correct particle size. The dry mix is passed through a pre-conditioner, in which other ingredients may be added, and steam is injected to start the cooking process. The preconditioned mix is then passed through an extruder, and then forced through a die where it is cut to the desired length. The cooking process takes place within the extruder where the product produces its own friction and heat due to the pressure generated (1020 bar). The extruding process can induce both protein denaturation and starch gelatinization, depending on inputs and parameters.

[edit]Drug

carriers

This section requires expansion. (August 2008)

Extrusion through nano-porous, polymeric filters is being used to manufacture suspensions of lipid vesicles liposomes or Transfersomes for use in pharmaceutical products. The anti-cancer drugDoxorubicin in liposome delivery system is formulated by extrusion, for example.

[edit]Biomass

briquettes

Main article: Biomass briquettes The extrusion production technology of fuel briquettes is the process of extrusion screw wastes (straw, sunflower husks, buckwheat, etc.) or finely shredded wood waste (sawdust) under high pressure when heated from 160 to 350 C. The resulting fuel briquettes do not include any of the binders, but one natural -

the lignin contained in the cells of plant wastes. The temperature during compression causes melting of the surface of bricks, making it more solid, which is important for the transportation of briquettes.

[edit]Design
The design of an extrusion profile has a large impact on how readily it can be extruded. The maximum size for an extrusion is determined by finding the smallest circle that will fit around the cross-section, this is called the circumscribing circle. This diameter, in turn, controls the size of the die required, which ultimately determines if the part will fit in a given press. For example, a larger press can handle 60 cm (24 in) diameter circumscribing circles for aluminium and 55 cm (22 in). diameter circles for steel and titanium.[1] The complexity of an extruded profile can be roughly quantified by calculating the shape factor, which is the amount of surface area generated per unit mass of extrusion. This affects the cost of tooling as well as the rate of production.[12] Thicker sections generally need an increased section size. In order for the material to flow properly legs should not be more than ten times longer than their thickness. If the cross-section is asymmetrical, adjacent sections should be as close to the same size as possible. Sharp corners should be avoided; for aluminium and magnesium the minimum radius should be 0.4 mm (1/64 in) and for steel corners should be 0.75 mm (0.030 in) and fillets should be 3 mm (0.12 in). The following table lists the minimum cross-section and thickness for various materials.[1]

Material

Minimum cross-section [cm (sq. in.)] Minimum thickness [mm (in.)]

Carbon steels 2.5 (0.40)

3.00 (0.120)

Stainless steel 3.0-4.5 (0.45-0.70)

3.00-4.75 (0.120-0.187)

Titanium

3.0 (0.50)

3.80 (0.150)

Aluminium

<2.5 (0.40)

1.00 (0.040)

Magnesium

<2.5 (0.40)

1.00 (0.040)

Ehow.com

Resin

The plastic extrusion process starts with what are called thermoplastic resins. Thermoplastic resins are a type of plastic which can be melted, processed, and then remelted to be used again. These resins are generally delivered in a pellet or bead form to be used in the plastic extrusion machinery. The pellets or beads can come in several different forms. There are plastic resin beads, which come in what is referred to as a virgin form. These are beads which have never been processed before and generally come with certifications of purity. The beads are also available in grades of quality that can be purchased for specific uses. Waste plastic from the extrusion process can be reprocessed into beads that may be used again, which reduces the overall waste generated in the process.

Machinery and Melting

Extrusion machinery can be complicated to operate, but the overall process is relatively straightforward. The heart of the machine is the screw, which sometimes is referred to as an auger. The screw is turned by a gearbox, which is powered by a motor. It is enclosed in a tight, heated barrel, which helps to provide friction. The thermoplastic pellets are delivered into the machine through a hopper. The hopper is located at the rear of the barrel/screw assembly and the pellets drop into the barrel from there. As the screw turns, it slowly drags the thermoplastic pellets forward. The heat from the friction of the screw turning inside the barrel--along with external heating-melts the plastic as it moves forward in the barrel. The melted plastic is pushed into a section designed to meter the plastic for the next stage in the process. It also may be subjected to pressurized pumping at this phase of the process.

Extrusion

Once the plastic has entered into metering section of the barrel, it is ready to be extruded into a die. The die is attached to the barrel and it represents the final shape or profile that the plastic is intended to take. The plastic is forced into the die. As the plastic moves forward into the die, it will be separated by a mandrel, which is centered in the extrusion channel. Pressurized air is forced though the mandrel structure as a means of keeping the plastic from collapsing as it moves through the die. As the plastic leaves the die, it will enter into a vacuum environment. Inside the vacuum, there are sizing rings meant to keep the plastic in the desired shape. The vacuum environment also will be filled with water as a means of cooling the extruded plastic. After the extruded plastic has passed through the water-filled vacuum environment it can be cut or spooled as appropriate.

Read more: How Does Plastic Extrusion Work? | eHow.com http://www.ehow.com/howdoes_5208405_plastic-extrusion-work_.html#ixzz29UGd6ijX

Britannica.com

Business.com

Plastic Extrusion Machines Key Terms

Learn the key terms of plastic extrusion machinery and equipment
inSh ar e

In order to buy plastic extrusion machines that are right for your company, you need to know plastic extrusion machines key terms. These key terms include the names of commonly used plastics and types of plastic extrusion machines. Learning these important key terms requires a basic understanding of chemistry and physics. Several resources are available to you, including simple explanations of the plastic extrusion process and scientific journal articles on how to achieve the best extruding results. When searching for information on plastic extrusion machines key terms, consider the following: 1. Know what is meant by thermoplastic and thermoset plastic materials. 2. Review attributes of a screw plastic extrusion machine. 3. Learn when to use ram plastic extrusion.

Know that thermoplastics are processed in extruder machines

Plastics that melt in high temperatures are categorized as thermoplastics. These types of plastics are a popular choice for plastic extrusion machinery because they are easier to mold than other plastics. Because the chemical property of thermoplastics doesn't change during the molding process, they can be repeatedly heated and remolded. Try: To learn more about thermoplastic materials and engineering, visit The A to Z of Materials. Although not exhaustive, the website provides a glossary of basic thermoplastic properties and applications. For an easy-to-understand explanation of what sets thermoplastics apart from other plastics, visit The Polymer Science Learning Center.

Become familiar with thermoset plastics processed in a plastic extrusion machine

Thermoset plastics, as opposed to thermoplastics, can be molded and heated only once. Thermoset plastics are more difficult to mold because they retain their shape and strength when heated; however, they are ideal for extruding large, permanent pieces.

Try: Read more about thermoset plastics at ThomasNet. To learn how thermoset plastics are made in comparison to other plastics, including thermoplastics, visit Machine Design.

Recognize the characteristics of screw plastic extrusion machines

Screw extruding machines are commonly used when extruding thermoplastics. Extrusion screws are divided into five zones. The first zone feeds the material into the extruder; the second zone melts the material; the third zone pressurizes the material so it's uniformly pressured; the fourth zone decompresses the material; and the fifth zone mixes the material. Try: Read a research study conducted on screw extrusion machines' melt temperatures at The SAO/NASA Astrophysics Data System. Find an article reviewing the twin-extruder process at the Institute of Physics.

Review information on ram plastic extrusion equipment

Ram plastic extruder machines are typically used when screw extruders can't process the material. In ram extrusion, the plastic, which is in powder form, is gravity fed into the machine's chamber. From the chamber, the plastic is forced into the die by a hydraulic ram. Try: Learn more about ram extrusion at Extruded Profile. The website offers a simple explanation of the process as well as photographs and diagrams. To read a scientific article on ram extrusion of re-enforced thermoplastics, visit Wiley InterScience.

Teel.com Extrusion Process

The extrusion process is a key component of many of our daily activities. It provides the tubing that distributes our drinking water, heats or cools our homes and could deliver life saving medication to a person in need. The process involves the use of polymers (plastics) that when heated change from a solid to a vicious liquid. Once the polymer is in its liquid state it is extruded (pushed) out a die that provides a specific shape. The process is contained in an extruder that consists of a round barrel with a screw inside. The polymer is placed into a hopper throat. As the screw rotates the polymer moves from the feed section up and through the die and takes shape of the orifice in the die. Once the part is extruded out of the die in the molten state it passes through a sizer to control the shape of the part as it cools. This can be done in many methods depending upon the material and line rate (feet per minute) in the process. Typically with tubing products a vacuum tank is used. The tank creates a vacuum chamber in which the part is passed thru. This forces the tube to push out against a sizer that is shaped and controls the size of the polymer until it is cooled below its melting point (Tg glass transition temperature). Similar methods to sizing are vacuum calibration, air racks and open water tanks. The polymer is cooled and then pulled thru a take off puller. The take off puller is a key component to maintaining and controlling the size of the extrusion. The puller must take the material being exited from the die thru the sizer at the same continuous rate. The puller is typically set to a constant speed that is relational to the extruder output. The puller speed is typically given feet per minute (fpm). The fpm is key to determining the amount of sizer required to control the polymer and provide the right size product required by the customer. Once the polymer is cooled and thru the take off puller then it can be cut to length, punched or formed to provide the finished product. Flexible products can be wound on spools or coils.

Wisegeek.com

An extrusion machine is a device which pushes or pulls a material through a shaped die to form a continuous length of product with a preset cross section. The extrusion process is used to produce a large number of commercial products which include steel or copper wire, plastic tubing, plastic sheets, and many food types. Extrusion as a manufacturing process offers many benefits such as the wide range of complex cross sections possible and the ability to form brittle materials. Depending on the material used, an extrusion machine may form the material cold or hot with some types of materials being completely melted prior to extrusion. The simplest example of an extrusion machine is a bakers piping bag. The bag is filled with icing and a fitted with a decorative piping nozzle. If the bag is squeezed, the icing fills the nozzle and is forced out or extruded as a continuous length with the same cross section as the shape of the nozzle opening. This is the same basic principle as industrial extrusion machines used to form many products using plastics, metals, and food or pharmaceutical ingredients. The only real departure from this simple example is in the complexity of the cross sections, the inclusion of hollow cores, and the fact that some machines draw the material through the die rather than pushing it. AdChoices

Plastic Extrusion Machine

Choose from 1M+ Verified Suppliers. Contact Directly & Get Live Quotes! www.alibaba.com/Extrusion-Machine

Aluminum Extrusion mfcrs

More than 245 kinds of profiles Curved Aluminum Profiles available in.misumi-ec.com/

Plastic Extruded Profiles

Competitively priced high quality extruded profiles. China based. www.i-profile.com.hk

Extruded Aluminium Sections

Leading Manufacturer & Supplier Of Aluminium Profile Extrusion.Enquire nishametals.in/call@9829069543 PE/PVC/PPR pipe production line manufacturer of pipe machinery www.87257222.com

pipe extrusion line

An extrusion machine can be used to produce a wide variety of products from an equally large range of raw materials. It is also an attractive alternative to other manufacturing processes as it allows for a larger selection of profiles and is suitable for use with brittle materials. In industrial applications, plastics are extruded to produce food packaging film, cladding sheets, insulation, automotive parts, and tubing products such as electrical conduit and plumbing pipes. Steel and

alloys are extruded to form rods, pipes, and wires as well as steel conduits and construction members for light engineering. The food and pharmaceutical industries also make extensive use of extrusions in the production of products such as pasta, cereals, cookies, and several drug carriers. In several extrusion applications, particularly those using plastics, the material to be extruded needs to be heated to melting point prior to being used. These applications typically use a screw feeder mechanism similar to those used in the injection molding process to heat and feed the material. Cold extrusion is also a common extrusion process and is normally limited to metals such as tin, lead, steel, aluminum, and copper. Cold extrusion has several benefits over the hot process such as a lack of oxidization, better surface finishes, and quicker extrusion times. A cold extrusion machine is used to produce items such as automotive pistons, steel cylinders, tubing, and gear blanks.

Sourcing.indiamart.com

The extrusion of polymers is quite different from extrusion of metals like aluminium. The billet material here is not in the form of a bar stock. Rather it comes in a powder or pellet form. The substance stated above is added to a machine. This machine utilizes a screw-type action for helping in mixing and pushing the plastic material via the die opening. The polymer is first fed onto a rotating screw, heated up and mixed. As soon as the melt reaches the die, it is allowed to pass through a screen pack. This screen pack consists of a series of wire meshes perfectly supported by a stiff plate (also known as a breaker plate) comprising small axial holes. An elementary polymer extrusion process line is shown here. Plastic extrusion process is actually polymer extrusion process only. It involves forming of a continuous piece of plastic as plastic material is forced via a shaping orifice with optional heat. The opening via which the resins are forced actually gives the product its basic shape and form. This process results in consistent thickness and gauge control. A basic process for manufacturing extruded Plastic Profiles goes like this. Plastic material in the form of pellet is fed an Extruder. The plastic is then conveyed forward, continuously by use of a rotating screw. It lies inside a heated barrel that gets softened by friction and heat. Then softened plastic is consequently forced out via a die into a cool water directly. Here the product solidifies. The extruded material is then conveyed onwards into take-off rollers. This rollers do the act of pulling the softened plastic from the die. The die is a sort of metal plate that is placed at the end of an extruder. A section is cut out from its interior. Actually the cross-section of the product gets determined by this cutout and speed of the take-off rollers. There are various types of extrusion process available depending on the various types of materials and user specification. With a Coextrusion process it's now possible to produce several different plastic types in a same production line. Extrusion is generally a process that is fully-automatic. It has continuous dimension checks and automatic machine adjustment, this makes it possible for the manufacturers to make simple tubes, rods to even complex window profiles. Extrusion process also enables manufacture of large products like pipes with diameter up to 150cm. Dual Durometer Extrusion A most common type of variation on the straight extrusion is the Dual Durometer Extrusion. Here, typically a "side machine" which is about one fourth or even less as compared to the size of main machine runs in tandem with the primary machine, feeding a separate material for example flexible vinyl with rigid PVC to the die. Here the streams

gets merged into a single extrusion constituted of double bonded profiles. They often display two hardnesses or dual durometers. The following image describes a typical dual durometer extrusion. Advantages of Dual Durometer Extrusion As two materials with different physical properties are joined, there is a combination of structural integrity as well as flexible function into one part. To illustrate the point as a rubber gasket is attached to a metal part for providing a closure seal, the dual durometer extrusion process integrates both functions into a single piece. Thus cosiderably reducing assembly cost and at the same time enhancing performance and function. Design considerations in plastic extrusion process Here's some of the design consideration in plastic extrusion process. Geometry of the part In a plastic extrusion process material melts down in a gradual manner as it travels through the barrel, and subsequently out of the die. Since it is typically in the form of a liquid as it exits the die, the wall thicknesses must remain uniform, along with the symmetrical shape. Otherwise, there is every chance that a greater pressure on one of the side can force the profile sideways, thus creating a "bow", in place of a straight part. A perfectly balanced shape permits maximum running speed, at a low cost. Hollowness in the profile can create knitlines, in the place where there is separation and rejoining of the material. Material used Most of the thermoplastics can be extruded, the long list includes materials like HDPE, LDPE, ABS, acetates, polystyrene, polypropylene, butyrates, acetals, nylons, polyphenylene sulfides, polycarbonates, thermoplastic polyesters and rubbers among others. Materials like nylon, are difficult to extrude as they become very fluid as they are melted. Others like acetal or butyrate comes with an objectionable odour thus resulting in very few takers for them. Tolerances As plastic extrusions are not contained fully by metal tooling, tolerances as a rule must typically be looser than the other types of molding processes. Specialized tooling can hold tighter tolerances, however the following are the "normal tolerances": Wall thickness: .005 Cut length: .062 or more Height or width: .010 per inch of width Straightness: 0.045 bow per foot Basic Die Design A tooling system for the basic die design comprises:

Flat Plate Die Plate that has the shape of the part cut through the die. However for guiding the material there is no transition. The flat plate die design is considered a low cost alternative for low volume production. Semi-streamlined Die Here at the back of the die the corners and edges have radii for helping in the transition of material into the die. Fully Streamlined Die In this case the die forcefully channels the material uniformly throughout the die. This design however is most expensive and well suited for high volume jobs. Secondary Operations Secondary operation for plastic extrusion process includes cutting, drilling, mitering of corners (especially for gaskets or frames), belling (to increase the diameter at the end), taping and cutting according to length. This process can be performed during extrusion (on-line), or after the process of extrusion (off-line). Off-line cutting generally is more complex and costly, but are known to hold tighter tolerances. Parameters in Plastic Extrusions There are certain basic standards which need to be met by plastic extrusions whenever the finished profiles are going to be used for industrial application. Efforts are to be made to remove defects like tearing and necking. Some of these parameters are: Dies used in the process must be of high quality and accurate. Frequent quality checks Good extrusion machinery Skilled manpower