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EXTRUSION

EXTRUSION. Film Blowing, Mono- and Multi-layer and Double Bubble Film Blowing. 3-layer 2 extruders. 3-layer 3 extruders. 5-layer 3 extruders. 7-layer 4 extruders. 5-layer 4 extruders. 7-layer 5 extruders. FILM BLOWING.

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EXTRUSION

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  1. EXTRUSION CORPORATE TRAINING AND PLANNING

  2. Film Blowing, Mono- and Multi-layer and Double Bubble Film Blowing 3-layer 2 extruders 3-layer 3 extruders 5-layer 3 extruders 7-layer 4 extruders 5-layer 4 extruders 7-layer 5 extruders FILM BLOWING There are two techniques of making film. One is the cast film process. The other is the blown film process. The difference in qualities is that the blown film is more christalline than the cast film AXON manufacture machinery for both processes CORPORATE TRAINING AND PLANNING

  3. Blown Film Co-Extrusion • Barrier properties is the main reason to go for multi layer film Five layer Co-Extrusion Three layer Co-Extrusion CORPORATE TRAINING AND PLANNING

  4. MULTILAYER BLOWN FILM Please check below a number of layer-designs from 2 layer up to 7 layers. The glue-layers are of great importance where two different polymers are not compatible 3-Layer head for 2 extruders -Layer head for 3 Extruders CORPORATE TRAINING AND PLANNING

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  7. Multilayer Film Dies • Two types of dies: 1.Feed Block 2.Multimanifold • In Feed Block the melt streams are brought together and flow out the die • In Multimanifold the melt spreads independently and meet at the die exit • Two types of process Oscillating Platform Oscillating Haul-Off CORPORATE TRAINING AND PLANNING

  8. Multimanifold three-layer flat-film die Feed Block MULTI LAYER FLAT FILM DIES CORPORATE TRAINING AND PLANNING

  9. Advantages of Multi-layer Film Two to seven layers depending on the application. It possesses good barrier properties against gas and moisture. High tensile,impact and tear strength. Good stiffness,optical,carrier and printing properties. e.g. LDPE/HDPE/LDPE,LLDPE/LDPE..etc. CORPORATE TRAINING AND PLANNING

  10. Sheet Extrusion Sheet is produced by forcing molten thermoplastic through a long horizontal slit die. The extruded hot web passes around metal cooling rolls and is then cut up or rolled up. • Material used : • HIPS is the most important sheet material. HDPE, PVC, ABS are also used. Sheet grades usually have high melt viscosity. CORPORATE TRAINING AND PLANNING

  11. Process Line • The sheet leaving from the slit die is picked up by vertical stack of three rolls. • The polishing rolls are usually chrome-plated and provided with temperature control by circulating oil. The polishing rolls imparts a good surface to the product without warpage. The temperature of the top rolls should be as high as possible without sticking, while the bottom roll should be just cool enough to prevent distortion. • From the polishing rolls the sheet passes along a conveyor, which consist of free running rollers. • The sheet is pulled by the pulling rolls are covered with elastomer. Their speed is adjusted to be slightly less than that of the polishing rolls to allow for shrinkage that takes place as the sheet cools. • The sheet is cut into desired dimensions by means of razor blades (thin sheets), shear cutting device (Standard sheets), or circular saws (thick sheets). CORPORATE TRAINING AND PLANNING

  12. Sheet Extrusion Line CORPORATE TRAINING AND PLANNING

  13. SHEET EXTRUSION ON 3-ROLLER CALANDERS CORPORATE TRAINING AND PLANNING

  14. Dies Dies used in sheet extrusion are similar to that of flat film dies. Various cross-section of a flat sheeting die is shown in fig Various Cross-Sections of Flat Sheeting Dies: Circular, Tear drop, Angular and Flat Teardrop CORPORATE TRAINING AND PLANNING

  15. Extrusion coating • The plastic is coated over a substrate like paper, by extruding through a slot die downward between two rolls. • Substrate is fed between the molten plastic and the roll and is joined with the plastic by pressure between rolls without the use of an adhesive. • Material used LDPE & PVC PP, HDPE, Ionomer etc. are also used. • Equipment compresses of • Pre treatment unit • Coating unit • Take off & winding Sketch of Paper Coating for Extrusion Process CORPORATE TRAINING AND PLANNING

  16. Dies • Coat hanger die • ‘T’ type die Manifold T-die : (a) Die Body, (b) Manifold, (c) Adjustable Lip and (d) Clamping Screw Coat-Hanger Die : (a) Die Body, (b) Manifold, (c) Fixed Jaw, (d) Movable Jaw, (e) Choker Bar, (f) Clamping Screw and (g) Jaw Adjusting Screw CORPORATE TRAINING AND PLANNING

  17. Wire Coating/Cable Covering • Unit comprises of • Un wind unit (For conductor) • Pre treatment unit • Wire coating unit • Steps Involved • Wire/conductor is unwound & straightened by Tension • Control Unit. • Pre treated to promote adhesion of molten plastic • Then passed through the Cross head die of the coating unit • Coated wire is then cooled by passing through cooling trough • Wound on the winder • Cooling Trough • Take off/ wind up. CORPORATE TRAINING AND PLANNING

  18. Wire Coating Extrusion Line Diagram of a production line for the coating of wire or cable with plastic. The conductor to be covered unwinds at the left, is preheated, passes into the crosshead die (center). The extruder is behind the die, and feeds it with molten plastic, which coats the conductor. The finished product is cooled, tested and wound up at the right. CORPORATE TRAINING AND PLANNING

  19. Die used • Tubing die USED MAINLY FOR PRIMARY INSULATION • Pressure die USED MAINLY FOR SECONDARY INSULATION CORPORATE TRAINING AND PLANNING

  20. Dies T-TYPE DIE COAT HANGER TYPE DIE ( Widely Used) Coat Hanger type of Die is much more stream lined than T-type Die CORPORATE TRAINING AND PLANNING

  21. Tube/Pipe Extrusion • Wall thickness & flexibility/Rigidity differentiates between tube/pipe • Pipes are produced by horizontally extruding molten polymer through an annuler opening into several sizing, cooling devices that stabilizes the final dimension. • Comprises of • Extruder • Die • Sizing device • Cooling bath • Cater puller • Cutter or winder CORPORATE TRAINING AND PLANNING

  22. DIES USED • STRAIGHT THROUGH OFF SET DIE CORPORATE TRAINING AND PLANNING

  23. Sizing Equipment - Methods • Vacuum Trough • Widely used • With the help of vacuum, Pipe is stabilized and sized to retain the shape • Sizing Sleeve • Methods fixes the outside pipe diameter as it hardens by contact with a water cooled metal sleeve. FLOATING PLUG SYSTEMS- USED FOR RIGID PIPES OF MEDIUM AND LARGE SIZES TO PREVENT LOSS OF AIR PRESSURE FLOATING PLUG SYSTEM IS USED CORPORATE TRAINING AND PLANNING

  24. Extended Mandrel • Method uses a water cooled extended mandrel • Provides additional internal cooling and internal support • Sizing plate • Method involves pulling the pipe through a series of brass plates • Mainly for small dia pipes/tubes. CORPORATE TRAINING AND PLANNING

  25. Extrusion of Mono filaments • Mono filaments are wise like polymer strands of dia 0.09 to 1.52 mm. • Usually they have circular cross-section. • The polymer melt from extruder is pumped out through a multi-hole die, quenched, stretched/oriented and annealed to get the filament of enhanced properties. • The production process comprises of • Extrusion • Filament forming • Stretching (orientation) • Annealing • Winding CORPORATE TRAINING AND PLANNING

  26. Orientation Systems A C Liquid-bath method Heated Point method D B Air - Oven method CORPORATE TRAINING AND PLANNING Cold Drawing

  27. Extrusion -- Box- Strappings • The process sketch is similar to Monofilament line except the die – A slotted die is used in place of multi-hole monofilament die • Plastic Strappings, made of PP/HDPE replace iron because of their flexibility. • Process outline • Plasticated melt from an extruder is pumped out through a slot die • Quenched in water bath • Bath temperature - 800C for PP • - 900C for PA-6 • Passed through a orientation system and stretched to about 8 times in order to improve tensile properties. • Annealed in an annealing chamber to relieve the stresses • Wound on winder. CORPORATE TRAINING AND PLANNING

  28. CORRUGATED PIPES • The characteristics of corrugated plastic pipes depend on profile and material. • Corrugated pipes have either parallel ring grooves or a continuous helical groove. • The pipes design can be single walled or twin walled. • Most common thermoplastics are PVC, PE,PP, PA and fluoropolymers. • The most important advantages are • Considerable raw material savings • High pressure resistance with good flexibility. • High impact strength • Good hydraulic characteristics CORPORATE TRAINING AND PLANNING

  29. Process Essentially IIIr to extrusion of pipes except that the die and the calibration units are specially designed to produce corrugation on the pipes. The cylindrical part of the pipe die head extends into the closed area of a revolving mould block chain. The plastic tube is pressed against the profiled, revolving mould block halves by internal air pressure or by vacuum calibration. As it passes through the forming machine, it is cooled by contact with the mould blocks, and by that time it reaches the end of the chain, the tube must be sufficiently cooled to leave the rotating mould blocks in a stable form. CORPORATE TRAINING AND PLANNING

  30. a--Pipe die head with Insert b--Compressed air inlet c-- Shaping die d -- Sealing stopper e -- Vacuum connection CORPORATE TRAINING AND PLANNING

  31. In order to let the pressure or vacuum sizing become effective, the molten tube must be brought over a special extended outer die ring as close as possible to the moulding chain –inlet. Otherwise the tube would be blown off in pressure sizing and fail in vacuum sizing.The extended position of the outer die ring cannot be heated separately. So that it must be made of a material of high thermal conductivity. CORPORATE TRAINING AND PLANNING

  32. Double walled corrugated pipe production: The manufacturing process is the same as with standard corrugated pipes, but when the first tube has been formed, the second tube is laid smoothly on the inner surface of the still plastic corrugation and welded to the first with the aid of a sizing mandrel. CORPORATE TRAINING AND PLANNING

  33. Double Walled Corrugated Pipe Production • -- Die for coextrusion • --Through flow guide • --Mandrel extrusion for inner layer • -- Shaping die CORPORATE TRAINING AND PLANNING

  34. Applications of Corrugated pipes are: • Conduits for cable protection, TV,Telephone, Glass fibre, power, control and computer lines, automobiles, machines and planes, protective pipes and conveyor pipes. • Drain pipes for fields, streets, squares and houses. • Pipes for vacuum cleaners, washing machines, dish washers, medical application – drip irrigation, hoses for fields, hot houses and plantations. • Protection pipes for district heating, domestic connection lines, structural and civil engineering. • Large size pipes for sewage, waste water, control shafts and conveyor pipes. Corrugated pipes are produced with diameters form 3\5 to 2000mm. CORPORATE TRAINING AND PLANNING

  35. POST EXTRUSION FORMING Inline postforming with extruder : Embossing one or both sides with shallow or deep patterns CORPORATE TRAINING AND PLANNING

  36. INLINE FIXED / ROTATING RINGS USED TO TWIST EXTRUDATE CORPORATE TRAINING AND PLANNING

  37. INLINE VACUUM/PRESSURE FORMER FOR PLASTIC SHEEET WITH MATCHED, WATER COOLED FORMING MOULDS ON CONTINOUS CONVEYOR SYSTEM AN INLINE COIL FORMER CAN PRODUCE TELEPHONE CORDS, SPRINGS, ETC., USING EXTRUDED ROUND, SQUARE, HEXAGONAL, AND OTHER SHAPES CORPORATE TRAINING AND PLANNING

  38. TROUBLE SHOOTING CORPORATE TRAINING AND PLANNING

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