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The Dynisco Extrusion Processors Handbook 2Nd Edition

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The Dynisco Extrusion Processors Handbook 2Nd Edition The Dynisco Extrusion Processors Handbook 2nd edition Written by: John Goff and Tony Whelan Edited by: Don DeLaney Acknowledgements We would like to thank the following people for their contributions to this latest edition of the DYNISCO Extrusion Processors Handbook. First of all, we would like to thank John Goff and Tony Whelan who have contributed new material that has been included in this new addition of their original book. In addition, we would like to thank John Herrmann, Jim Reilly, and Joan DeCoste of the DYNISCO Companies and Christine Ronaghan and Gabor Nagy of Davis-Standard for their assistance in editing and publication. For the fig- ures included in this edition, we would like to acknowledge the contributions of Davis- Standard, Inc., Krupp Werner and Pfleiderer, Inc., The DYNISCO Companies, Dr. Harold Giles and Eileen Reilly. CONTENTS SECTION 1: INTRODUCTION TO EXTRUSION Single-Screw Extrusion . .1 Twin-Screw Extrusion . .3 Extrusion Processes . .6 Safety . .11 SECTION 2: MATERIALS AND THEIR FLOW PROPERTIES Polymers and Plastics . .15 Thermoplastic Materials . .19 Viscosity and Viscosity Terms . .25 Flow Properties Measurement . .28 Elastic Effects in Polymer Melts . .30 Die Swell . .30 Melt Fracture . .32 Sharkskin . .34 Frozen-In Orientation . .35 Draw Down . .36 SECTION 3: TESTING Testing and Standards . .37 Material Inspection . .40 Density and Dimensions . .42 Tensile Strength . .44 Flexural Properties . .46 Impact Strength . .47 Hardness and Softness . .48 Thermal Properties . .49 Flammability Testing . .57 Melt Flow Rate . .59 Melt Viscosity . .62 Measurement of Elastic Effects . .64 Chemical Resistance . .66 Electrical Properties . .66 Optical Properties . .68 Material Identification . .70 SECTION 4: THE SCREW AND BARREL SYSTEM Materials Handling . .72 The Hopper . .75 The Barrel . .76 The Screw . .79 Screw Types . .83 Screw Mixing Sections . .87 Breaker Plates, Screen Packs, and Gear Pumps . .92 Screw Drive System . .96 Motor Size and Thrust Bearing Life . .99 SECTION 5: THE DIE AND POST EXTRUSION EQUIPMENT Die Design Criteria . .101 Materials of Die Construction . .103 Die Heating . .105 Flat Film and Sheet Dies . .107 Blown Film Dies . .108 Pipe Dies . .111 Wire and Cable Covering Dies . .113 Profile Dies . .114 Cooling . .115 Extrudate Take Up . .116 Cutting and Stacking . .118 SECTION 6: EXTRUSION OPERATIONS Start Up . .119 Process Monitoring . .122 Process Control . .127 Shut Down Procedures . .130 Purging . .130 Stripping and Cleaning . .133 Reclaimed Material . .136 Machine Setting and Running . .139 SECTION 7: DEFECTS AND DEFECT FINDING Defect Determination . .143 Minimizing Defects . .145 Extrusion Defects and Causes . .146 Production Problems and Flow Behavior . .147 SECTION 8: GUIDELINES FOR THE FOLLOWING MATERIALS ABS (Acrylonitrile-Butadiene-Styrene) . .150 HIPS (High Impact Polystyrene) . .159 PA 6 (Nylon 6) . .165 PA 66 (Nylon 66) . .175 LDPE (Low Density Polyethylene) . .183 LLDPE (Linear Low Density Polyethylene) . .191 HDPE (High Density Polyethylene) . .198 PP (Polypropylene) . .206 PMMA (Polymethyl Methacrylate) . .216 PPVC (Plasticized Polyvinyl Chloride) . .223 UPVC (Unplasticized Polyvinyl Chloride) . .234 SECTION 9: USEFUL INFORMATION SI Units Advice on Use . .245 Unit Conversion . .246 Temperature Conversion . ..
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