Troubleshooting the Extrusion Process : A Systematic Approach to Solving Plastic Extrusion Problems,9781569903209

Troubleshooting the Extrusion Process : A Systematic Approach to Solving Plastic Extrusion Problems

by ;
ISBN13: 9781569903209
ISBN10: 1569903204
Format: Hardcover
Pub. Date: 2001-09-01
Publisher(s): Hanser Gardner Pubns
List Price: $89.95

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Summary

Troubleshooting extrusion problems is one of the most challenging tasks for everyone involved in extrusion operations. It requires a good understanding of the extrusion process, knowledge of the material properties, good instrumentation, good analysis tools, and a systematic and logical approach.

Table of Contents

Requirements for Efficient Troubleshooting
1(7)
Instrumentation
1(1)
Understanding the Extrusion Process
2(1)
Collection and Analysis of Historical Data (Time Line)
2(2)
Team Building
4(1)
Condition of the Equipment
4(1)
Information about the Feed Stock
4(3)
Tools for Troubleshooting
7(14)
Temperature Measurement Devices
7(1)
Data Acquisition Systems
7(4)
Portable Data Collectors/Machine Analyzers
8(1)
Fixed-Station Data Acquisition Systems
9(2)
Light Microscopy
11(1)
Thermochromic Materials
12(1)
Thermal Analysis
13(6)
Differential Thermal Analysis and Differential Scanning Calorimetry
13(2)
Thermogravimetric Analysis
15(1)
Fourier Transform Infrared Spectroscopy
16(1)
Thermomechanical Analysis
17(1)
Torque Rheometer
17(1)
Other Thermal Characterization Techniques
18(1)
Miscellaneous Tools
19(2)
Systematic Troubleshooting
21(86)
Upsets versus Development Problems
21(1)
Machine-Related Problems
21(29)
The Drive System
21(2)
The Feed System
23(1)
The Heating and Cooling System
23(1)
Wear Problems
24(1)
Wear Mechanisms
25(1)
Test Methods for Wear
26(4)
Causes of Wear
30(6)
Solutions to Wear Problems
36(5)
Rebuilding Worn Screws and Barrels
41(4)
Screw Binding
45(1)
Introduction
45(1)
The Mechanics of Screw Binding
45(1)
Changes in Clearance Due to Temperature Differences
46(2)
Analysis of Temperature Distribution in Extruder Screws
48(1)
Change in Clearance Due to Compressive Load
49(1)
Results from Analysis
49(1)
Polymer Degradation
50(21)
Types of Degradation
50(1)
Thermal Degradation
51(1)
Mechanical Degradation
51(1)
Chemical Degradation
52(2)
Degradation in Extrusion
54(1)
Residence Time Distribution
54(4)
Temperature Distribution Simple Calculations
58(4)
Temperature Distribution Numerical Calculations
62(8)
Reducing Degradation
70(1)
Extrusion Instabilities
71(24)
Frequency of Instability
71(1)
High-Frequency Instabilities
72(3)
Screw Frequency Instabilities
75(1)
Low-Frequency Instabilities
76(1)
Very Slow Fluctuations
77(1)
Random Fluctuations
77(2)
Functional Instabilities
79(1)
Solids-Conveying Instabilities
79(1)
Plasticating Instabilities
79(1)
Melt-Conveying Instabilities
80(1)
Devolatilization Instabilities
81(1)
Mixing Related Instabilities
81(1)
Distributive Mixing Sections
81(5)
Dispersive Mixing Sections
86(6)
Solving Mixing Problems
92(1)
Solving Extrusion Instabilities
93(2)
Air Entrapment
95(1)
Gel Problems
96(4)
Measuring Gels
97(1)
Gels Created in the Extrusion Process
98(1)
Removing Gels Produced in Polymerization
99(1)
Die-Flow Problems
100(7)
Melt Fracture
100(2)
Die-Lip Buildup (``Die Drool'')
102(1)
V- or W-Patterns
103(1)
Specks and Discoloration
103(1)
Lines in Extruded Product
104(1)
Weld Lines
104(1)
Optical and Appearance Properties
105(2)
Case Studies
107(32)
Film Coextrusion-Degradation in the Middle Layer
107(3)
Description of the Problem
107(1)
Analysis of the Problem
107(1)
Solution
108(2)
Film Coextrusion with Interfacial Problems
110(1)
Description of the Problem
110(1)
Analysis of the Problem
110(1)
Solution
111(1)
Lines in the Extruded Film
111(2)
Description of the Problem
111(1)
Analysis of the Problem
112(1)
Solution
112(1)
Color Variation in Polypropylene Carpet Fiber
113(3)
Description of the Problem
113(1)
Analysis of the Problem
114(1)
Solution
114(2)
Plastic Film with Poor Transparency
116(2)
Description of the Problem
116(1)
Analysis of the Problem
116(2)
Solution
118(1)
Wear Problem in Film Extrusion
118(1)
Description of the Problem
118(1)
Solution
119(1)
Multilayer Film-Several Appearance Problems
119(2)
Problem Description
119(1)
Analysis of the Problem
120(1)
Solution
120(1)
Dispersion Problem in a High-Density Polyethylene Bottle
121(3)
Description of the Problem
121(1)
Analysis of the Problem
122(1)
Solution
122(2)
Polymer Degradation
124(4)
Description of the Problem
124(1)
Analysis of the Problem
124(2)
Solution
126(2)
Heat-Sealing Problems in a Coextruded Film
128(2)
Problem Description
128(1)
Analysis of the Problem
128(1)
Solution
129(1)
Output Problem in a Blown Film Line
130(3)
Description of the Problem
130(1)
Analysis of the Problem
131(1)
Solution
132(1)
Master Batch Selection
133(3)
Description of the Problem
133(1)
Analysis of the Problem
134(1)
Solution
135(1)
Pipe Extrusion Problem
136(3)
Description of the Problem
136(1)
Analysis of the Problem
136(1)
Solution
136(3)
References 139(4)
Appendices 143(12)
Appendix 1 Systematic Problem Solving
143(2)
Appendix 2 Machine Troubleshooting and Maintenance
145(8)
2.1 Check the Oil
145(1)
2.2 Unusual Noises
146(1)
2.3 Vibration Monitoring
146(1)
2.4 Drive Motors and Belts
147(1)
2.5 Spare Parts
148(1)
2.6 Screw and Barrel
148(1)
2.7 Extruder Maintenance Checklist
148(5)
Appendix 3 Setting Extruder Temperatures
153(2)
Index 155

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