Optimization of Execution Microscopic Extrusion Parameter Characterizations for Color Polycarbonate Grading: General Trend and Box–Behnken Designs (2025)

Extrusion-The-Definitive-Processing-Guide-and-Handbook

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An Integrative Simulation for Mixing Different Polycarbonate Grades with the Same Color: Experimental Analysis and Evaluations

Crystals, 2022

The processing parameters’ impact such as temperature (Temp.), feed rate (F.R.), and speed (S.) at three distinct grades of the same color was explored in this study. To investigate the effect of the characteristics on color formulations, they were each adjusted to five different levels. For these grades, which were all associated with the same color, an intermeshing twin-screw extruder (TSE) was used. The compounded materials were molded into flat coupons then evaluated with a spectrophotometer for their CIE (L*, a*, b*, and dE*) values. A spectrophotometer was used to determine the color of a compounded plastic batch, which measured three numbers indicating the tristimulus values (CIE L*a*b*). The lightness axis, which ranged from 0 (black) to 100 (white), is known as the L*-axis (white). Redness-greenness and yellowness-blueness were represented by the other two coordinates, a* and b*, respectively. The color difference deviation (Delta E*) from a target was dimensionless, when d...

Extrusion Product Quality Using Some SPC Tools

The quality of any extruded product is a function of various factors, such as chemical composition, geometric dimensions, appearance and regularity of the microstructure, variation of mechanical properties over the extruded length and cross section, and surface finish. Technical and economic viability of an extrusion plant depends on the minimization of defects that lead to product rejection. Attempts at improvement of extrusion quality and productivity thus translate straightaway into an analysis of product defects.

Box–Behnken Design for Polycarbonate-Pigment Blending: Applications and Characterization Techniques

Polymers

Incorporating pigments into polymers can be done for various purposes, including the introduction of color, interfacial effects, or aesthetics. If these pigments are to disperse properly, then the process of extrusion must be optimized. During polymer compounding extrusion, three effective processing factors were investigated: feed rate (FR), speed (Sp.) and temperature (temp.) for a colored compounded polycarbonate (PC) grade (30/70%). The processing design techniques were obtained by applying design experiments in a response surface methodology (RSM) to blend two polycarbonates with pigments and optimize the processing temperatures at center points. The first study decided to utilize the response surface approach of Box–Behnken design (BBD) to design an experiment to optimize the process parameters. Statistical significance was demonstrated by the model passing all diagnostic tests. Furthermore, the three processing factors strongly impacted the characteristics of the tri-stimulus...

Design, Simulation, and Analysis of the Extrusion Process of a PVC Thermoplastic Profile to Optimize the Design of the Die and the Machine Parameters

Fiber-Reinforced Plastics [Working Title], 2022

The objective of this work is to verify the design of an existing die for the manufacture of an extruded profile using the simulation of the flow in the head using a simulation software that uses computational fluid dynamics and also the experimental design and construction of a calibrator by means of the extrusion the geometry and desired dimensions of the profile. The rheological behavior of rigid PVC in the extruded molten state was investigated, which in itself is a difficult target due to the intrinsic weakness of this polymer that degrades when heated above 140°C. By means of a special capillary rheometer, rheological data, k and n of the power law, were obtained to introduce them, together with the process input parameters and the flow channel geometry in the simulation software. The flow channel was drawn with the head and calibrator using CAD-3D software. The different parts of the calibrator were manufactured and assembled into the equipment. The extrusion was performed wi...

Influence of low density polyethylene quality on extrusion coating processability

Polymer Engineering and Science, 1978

In order to obtain explicit information about the influence of different low density polyethylene (LDPE) quality parameters on extrusion coatingprocessability, a test run was made with an autoclave reactor and the products were investigated. All the grades manufactured had melt indices (MI), densities, molecular weight distributions (MWD), and degrees of long chain branching (LCB) typical of commercial extrusion coating grades. The processability characteristics studied were maximum line speed and neck-in. The influence of MI, density, and extrusion melt temperature were systematically investigated. It was found that the maximum line speed rose with increasing MI, density, and extrusion melt temperature, and that an increasing extrusion melt temperature led to a growing difference between the maximum line speed at a constant coating thickness and the maximum line speed at a constant screw speed. Neck-in was found to increase with increasing MI, increasing density, and increasing coating thickness. These effects were more pronounced at higher extrusion melt temperatures. When using the extrusion temperature needed to achieve a certain line speed for each grade, the influence of MI on neck-in was practically non-existent.

Recent Developments in Profile Extrusion : Automatic Design of Extrusion Dies and Calibrators

2007

This work describes the current state of the numerical codes that have been developed, by the authors, to aid the design of tools for thermoplastic profile extrusion. The main problems associated with the automatic design approach employed both for the extrusion die, forming stage, and calibrator, cooling/calibration stage, will be described. Two case studies are employed to illustrate the current code capabilities.

The Effect of Acetone as a Post-Production Finishing Technique on Entry-Level Material Extrusion Part Quality

South African Journal of Industrial Engineering, 2018

Entry-level material extrusion artefacts persistently suffer from questionable weakened end-product production quality, according to industrial standards. These limitations can be addressed by the development of improved finishing techniques that may narrow the gap between low-cost and high-end production methods in additive manufacturing. In doing so, the technology may become available to a larger spectrum of prosumers who previously were reluctant to use entry-level technology because of these limitations. This article describes the effect that acetone has as a post-production finishing technique for low-cost artefact production. Through a series of quantitative investigations, the study provides evidence that acetone reduces the tensile strength, increases polymer ductility, and significantly reduces the surface profile roughness of thermoplastics such as acrylonitrile butadiene styrene. The potential cost and waste reduction for entry-level manufactured products can then be identified.

Influence of molecular parameters on material processability in extrusion processes

Polymer Engineering & Science, 1999

A viscosity model showing a direct correlation between molecular weight distributions and shear thinning behavior of polymeric melts was used in 3D numerical simulations of an extrusion process. The equipment analyzed was a single screw extruder with an annular die attached. The material of choice in the simulations was polystyrene in a range of molecular weights and degrees of polydispersity. The influence of material parameters (molecular weight and polydispersity) on the system operating point, power consumption and residence time distribution was analyzed. The results were generalized and a window of processing conditions for resins with different properties was analyzed. The effect of blending homologous polymers with different molecular parameters on material processability was also presented. The model can be extended to other materials and various processing equipment.

Study on processing–microstructure–properties relationships of extruded profiles

Plastics, Rubber and Composites, 2006

In the present work, a rectangular polypropylene profile was produced under different extrusion conditions, in order to identify the most relevant processing variables determining its microstructure and mechanical properties and to understand the relationships between them. A Taguchi design of experiments technique, considering two levels for each variable (operating conditions), was used to define the set of extrusion runs. The resulting plastic profiles were characterised according to their microstructure and mechanical properties. It was concluded that the most significant processing variable determining the mechanical properties of the extrusion profiles is the extrusion temperature and that the drawdown ratio controls the degree of molecular orientation of the profiles, and therefore, the extension of shrinkage after heating.