Verfügbarkeit: Analyzing and troubleshooting single-screw extruders

Analyzing and troubleshooting single-screw extruders:

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Bibliographische Detailangaben
Hauptverfasser:	Campbell, Gregory A. (VerfasserIn), Spalding, Mark A. (VerfasserIn)
Format:	Buch
Sprache:	English
Veröffentlicht:	Cincinnati, Ohio Hanser Publications [2021] München Hanser Publishers [2021]
Ausgabe:	2nd Edition
Schlagworte:	Fehlersuche Einschneckenextruder Extrudieren Extrusion Kunststoffe Kunststoffverarbeitung FBKTEXTR: Extrudieren PLAS2020
Online-Zugang:	Inhaltsverzeichnis
Beschreibung:	XIX, 825 Seiten Illustrationen, Diagramme 25 cm
ISBN:	9781569907849 1569907846

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Datensatz im Suchindex

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adam_text	CONTENTS PREFACE ................................................................................................................ V ACKNOWLEDGEMENTS ....................................................................................... VII 1 SINGLE-SCREW EXTRUSION: INTRODUCTION AND TROUBLESHOOTING .. 1 1.1 ORGANIZATION OF THIS BOOK .......................................................................... 3 1.2 TROUBLESHOOTING EXTRUSION PROCESSES ...................................................... 5 1.2.1 THE INJECTION MOLDING PROBLEM AT SATURN .................................. 5 1.3 INTRODUCTION TO SCREW GEOMETRY .............................................................. 6 1.3.1 SCREW GEOMETRIC QUANTITATIVE CHARACTERISTICS .......................... 8 1.4 SIMPLE FLOW EQUATIONS FOR THE METERING SECTION .................................... 11 1.5 EXAMPLE CALCULATIONS ................................................................................ 15 1.5.1 EXAMPLE 1: CALCULATION OF ROTATIONAL AND PRESSURE FLOW COMPONENTS ................................................................................... 15 1.5.2 EXAMPLE 2: FLOW CALCULATIONS FOR A PROPERLY OPERATING EXTRUDER ......................................................................................... 18 1.5.3 EXAMPLE 3: FLOW CALCULATIONS FOR AN IMPROPERLY OPERATING EXTRUDER ......................................................................................... 18 1.5.4 METERING CHANNEL CALCULATION SUMMARY .................................... 20 NOMENCLATURE ..................................................................................................... 20 REFERENCES ........................................................................................................... 22 2 POLYMER MATERIALS ................................................................................. 23 2.1 INTRODUCTION AND HISTORY ........................................................................... 24 2.1.1 HISTORY OF NATURAL POLYMERS ........................................................ 25 2.1.2 THE HISTORY OF SYNTHETIC POLYMERS .............................................. 26 2.2 CHARACTERISTICS OF SYNTHETIC POLYMERS ...................................................... 28 2.3 STRUCTURE EFFECTS ON PROPERTIES ............................................................... 31 2.3.1 STEREOCHEMISTRY ........................................................................... 34 2.3.2 MELTING AND GLASS TRANSITION TEMPERATURES .............................. 35 2.3.3 CRYSTALLINITY ................................................................................... 37 2.4 POLYMER PRODUCTION AND REACTION ENGINEERING ...................................... 40 2.4.1 CONDENSATION REACTIONS ................................................................ 40 2.4.2 ADDITION REACTIONS ........................................................................ 43 2.5 POLYMER DEGRADATION .................................................................................. 46 2.5.1 CEILING TEMPERATURE ...................................................................... 49 2.5.2 DEGRADATION OF VINYL POLYMERS .................................................... 51 2.5.3 DEGRADATION OF CONDENSATION POLYMERS ....................................... 53 REFERENCES ............................................................................................................ 54 3 INTRODUCTION TO POLYMER RHEOLOGY FOR EXTRUSION ........................... 57 3.1 INTRODUCTION TO THE DEFORMATION OF MATERIALS .......................................... 57 3.2 INTRODUCTION TO BASIC CONCEPTS OF MOLECULAR SIZE .................................. 58 3.2.1 SIZE DISTRIBUTION EXAMPLE ............................................................. 59 3.2.2 MOLECULAR WEIGHT DISTRIBUTIONS FOR POLYMERS ............................ 60 3.3 BASIC RHEOLOGY CONCEPTS .......................................................................... 63 3.4 POLYMER SOLUTION VISCOSITY AND POLYMER MOLECULAR WEIGHT .................. 68 3.4.1 SAMPLE CALCULATION OF SOLUTION VISCOSITY .................................... 71 3.5 INTRODUCTION TO VISCOELASTICITY .................................................................. 72 3.6 MEASUREMENT OF POLYMER VISCOSITY .......................................................... 80 3.6.1 CAPILLARY RHEOMETERS .................................................................... 81 3.6.2 CONE AND PLATE RHEOMETERS .......................................................... 91 3.6.3 MELT INDEX AND MELT FLOW RATE .................................................... 95 3.7 VISCOSITY OF POLYMERS AS FUNCTIONS OF MOLECULAR CHARACTER, TEMPERATURE, AND PRESSURE ........................................................................ 98 3.8 HISTORICAL MODELS FOR NON-NEWTONIAN FLOW .............................................. 103 3.9 POWER LAW AND VISCOSITY SHEAR RATE DEPENDENCE .................................. 105 3.9.1 SHEAR STRESS FROM NEWTONIAN TO INFINITE SHEAR .......................... 105 3.9.2 VISCOSITY AS A FUNCTION OF SHEAR RATE .......................................... 106 3.9.3 THE POWER LAW AND PROCESS DISSIPATION .................................... 107 3.9.4 VISCOSITY, SHEAR RATE, AND DISSIPATION ........................................ 107 3.9.5 PERCOLATION IN STRUCTURED SYSTEMS .............................................. 110 3.9.6 TUBE FLOW DATA AND DATA ANALYSIS .............................................. 110 3.9.7 DISPERSION BASED POWER LAW CONSTANT N .................................... 112 3.9.8 RHEOLOGICAL IMPLICTIONS FOR EXTRUSION AND MOLDING PROCESSES 126 NOMENCLATURE ...................................................................................................... 130 REFERENCES ........................................................................................................... 133 4 RESIN PHYSICAL PROPERTIES RELATED TO PROCESSING ...................... 137 4.1 BULK DENSITY AND COMPACTION .................................................................. 138 4.1.1 MEASUREMENT OF BULK DENSITY ...................................................... 139 4.1.2 MEASURING THE COMPACTION CHARACTERISTICS OF A RESIN .............. 140 4.2 LATERAL STRESS RATIO * .......................................................... 143 4.2.1 MEASURING THE LATERAL STRESS RATIO .............................................. 144 4.3 STRESS AT A SLIDING INTERFACE ...................................................................... 146 4.3.1 THE SCREW SIMULATOR AND THE MEASUREMENT OF THE STRESS AT THE INTERFACE .............................................................................. 147 4.4 MELTING FLUX ............................................................................................... 149 4.5 HEAT CAPACITY ............................................................................................. 151 4.6 THERMAL CONDUCTIVITY AND HEAT TRANSFER ................................................ 153 4.7 MELT DENSITY ............................................................................................... 154 NOMENCLATURE ..................................................................................................... 156 REFERENCES ........................................................................................................... 156 5 SOLIDS CONVEYING ................................................................................... 159 5.1 DESCRIPTION OF THE SOLIDS CONVEYING PROCESS .......................................... 160 5.2 LITERATURE REVIEW OF SMOOTH-BORE SOLIDS CONVEYING MODELS ................ 162 5.2.1 DARNELL AND MOL MODEL ................................................................. 165 5.2.2 TADMOR AND KLEIN MODEL .............................................................. 166 5.2.3 CLARKSON UNIVERSITY MODELS ........................................................ 167 5.2.4 HYUN AND SPALDING MODEL ........................................................... 170 5.2.5 MOYSEY AND THOMPSON MODEL ...................................................... 171 5.3 MODERN EXPERIMENTAL SOLIDS CONVEYING DEVICES .................................... 171 5.3.1 SOLIDS CONVEYING DEVICES AT CLARKSON UNIVERSITY ...................... 172 5.3.2 THE SOLIDS CONVEYING DEVICE AT DOW .......................................... 186 5.4 COMPARISON OF THE MODIFIED CAMPBELL-DONTULA MODEL WITH EXPERIMENTAL DATA ..................................................................................... 196 5.4.1 SOLIDS CONVEYING EXAMPLE CALCULATION ...................................... 200 5.5 GROOVED BORE SOLIDS CONVEYING ............................................................... 202 5.5.1 GROOVED BARREL SOLIDS CONVEYING MODELS .................................... 206 5.6 SOLIDS CONVEYING NOTES ............................................................................. 208 NOMENCLATURE ..................................................................................................... 211 REFERENCES ........................................................................................................... 213 6 THE MELTING PROCESS .............................................................................. 217 6.1 COMPRESSION RATIO AND COMPRESSION RATE .............................................. 219 6.2 THE MELTING PROCESS .................................................................................. 221 6.2.1 THE MELTING PROCESS AS A FUNCTION OF SCREW GEOMETRY ............ 222 6.2.2 REVIEW OF THE CLASSICAL LITERATURE ................................................ 227 6.2.3 REEVALUATION OF THE TADMOR AND KLEIN MELTING DATA ................ 228 6.3 THEORY DEVELOPMENT FOR MELTING USING SCREW ROTATION PHYSICS .......... 231 6.3.1 MELTING MODEL FOR A CONVENTIONAL TRANSITION SECTION USING SCREW ROTATION PHYSICS ................................................................ 232 6.3.2 MELTING MODELS FOR BARRIER SCREW SECTIONS ................................ 246 6.4 EFFECT OF PRESSURE ON MELTING RATE ............................................................ 255 6.5 ONE-DIMENSIONAL MELTING .......................................................................... 256 6.5.1 ONE-DIMENSIONAL MELTING MODEL .................................................. 260 6.6 SOLID BED BREAKUP ...................................................................................... 262 6.7 MELTING SECTION CHARACTERISTICS ................................................................ 266 NOMENCLATURE ............................................................................................... 268 REFERENCES ............................................................................................................ 270 7 FLUID FLOW IN METERING CHANNELS ...................................................... 275 7.1 INTRODUCTION TO THE REFERENCE FRAME ........................................................ 275 7.2 LABORATORY OBSERVATIONS ............................................................................ 278 7.3 LITERATURE SURVEY ........................................................................................ 282 7.4 DEVELOPMENT OF LINEARIZED FLOW ANALYSIS ............................................. 287 7.4.1 EXAMPLE FLOW CALCULATION ............................................................ 303 7.5 NUMERICAL FLOW EVALUATION ........................................................................ 306 7.5.1 SIMULATION OF A 500 MM DIAMETER MELT-FED EXTRUDER ............... 308 7.5.2 EXTRUSION VARIABLES AND ERRORS .................................................... 310 7.5.3 CORRECTIONS TO ROTATIONAL FLOW .................................................... 316 7.5.4 SIMULATION OF THE 500 MM DIAMETER EXTRUDER USING F C ............. 321 7.6 FRAME DEPENDENT VARIABLES ...................................................................... 322 7.6.1 EXAMPLE CALCULATION OF ENERGY DISSIPATION ................................ 325 7.7 VISCOUS ENERGY DISSIPATION AND TEMPERATURE OF THE RESIN IN THE CHANNEL ........................................................................................................ 326 7.7.1 ENERGY DISSIPATION AND CHANNEL TEMPERATURE FOR SCREW ROTATION .......................................................................................... 332 7.7.2 ENERGY DISSIPATION AND CHANNEL TEMPERATURE FOR BARREL ROTATION .......................................................................................... 336 7.7.3 TEMPERATURE INCREASE CALCULATION EXAMPLE FOR A SCREW PUMP 337 7.7.4 HEAT TRANSFER COEFFICIENTS ............................................................ 342 7.7.5 TEMPERATURE CALCULATION USING A CONTROL VOLUME TECHNIQUE .. 343 7.7.6 NUMERICAL COMPARISON OF TEMPERATURES FOR SCREW AND BARREL ROTATIONS ........................................................................................ 346 7.8 METERING SECTION CHARACTERISTICS ............................................................... 348 NOMENCLATURE ...................................................................................................... 350 REFERENCES ........................................................................................................... 354 8 MIXING PROCESSES FOR SINGLE-SCREW EXTRUDERS ............................. 359 8.1 COMMON MIXING OPERATIONS FOR SINGLE-SCREW EXTRUDERS ...................... 360 8.1.1 COMMON MIXING APPLICATIONS ...................................................... 361 8.2 DISPERSIVE AND DISTRIBUTIVE MIXING PROCESSES ........................................ 363 8.3 FUNDAMENTALS OF MIXING ............................................................................ 365 8.3.1 MEASURES OF MIXING ...................................................................... 366 8.3.2 EXPERIMENTAL DEMONSTRATION OF MIXING ...................................... 368 8.4 THE MELTING PROCESS AS THE PRIMARY MECHANISM FOR MIXING ................ 376 8.4.1 EXPERIMENTAL ANALYSIS OF THE MELTING AND MIXING CAPACITY OF A SCREW ...................................................................................... 379 8.4.2 MIXING AND BARRIER-FLIGHTED MELTING SECTIONS ........................... 382 8.5 SECONDARY MIXING PROCESSES AND DEVICES .............................................. 383 8.5.1 MADDOCK-STYLE MIXERS .................................................................. 384 8.5.2 BLISTER RING MIXERS ........................................................................ 393 8.5.3 SPIRAL DAM MIXERS ........................................................................ 395 8.5.4 PIN-TYPE MIXERS ........................................................................... 396 8.5.5 KNOB MIXERS ................................................................................. 397 8.5.6 GEAR MIXERS ................................................................................... 398 8.5.7 DYNAMIC MIXERS ........................................................................... 399 8.5.8 STATIC MIXERS ................................................................................. 401 8.6 MIXING USING NATURAL RESINS AND MASTERBATCHES ................................... 408 8.7 MIXING AND MELTING PERFORMANCE AS A FUNCTION OF FLIGHT CLEARANCE ... 409 8.8 HIGH PRESSURES DURING MELTING AND AGGLOMERATES ................................ 410 8.9 EFFECT OF DISCHARGE PRESSURE ON MIXING ................................................. 410 8.10 SHEAR REFINEMENT ..................................................................................... 411 8.11 DIRECT COMPOUNDING USING SINGLE-SCREW EXTRUDERS .............................. 413 NOMENCLATURE ..................................................................................................... 414 REFERENCES ........................................................................................................... 416 9 SCALING OF SINGLE-SCREW EXTRUSION PROCESSES .............................. 421 9.1 SCALING RULES .............................................................................................. 422 9.2 ENGINEERING DESIGN METHOD FOR PLASTICATING SCREWS .............................. 423 9.2.1 PROCESS ANALYSIS AND SIMULATIONS .............................................. 427 9.3 SCALE-UP FROM A 40 MM DIAMETER EXTRUDER TO AN 80 MM DIAMETER MACHINE FOR A PE RESIN .............................................................................. 427 9.4 RATE INCREASE FOR AN 88.9 MM DIAMETER EXTRUDER RUNNING A HIPS RESIN 431 NOMENCLATURE ...................................................................................................... 438 REFERENCES ............................................................................................................ 439 10 INTRODUCTION TO TROUBLESHOOTING THE EXTRUSION PROCESS .......... 441 10.1 THE TROUBLESHOOTING PROCESS .................................................................... 442 10.2 HYPOTHESIS SETTING AND PROBLEM SOLVING ................................................ 445 10.2.1 CASE STUDY FOR THE DESIGN OF A NEW RESIN .................................. 446 10.2.2 CASE STUDY FOR A SURFACE BLEMISH ................................................ 448 10.2.3 CASE STUDY FOR A PROFILE EXTRUSION PROCESS ................................ 449 10.3 EQUIPMENT AND TOOLS NEEDED FOR TROUBLESHOOTING ................................ 450 10.3.1 MADDOCK SOLIDIFICATION EXPERIMENT ............................................ 452 10.4 COMMON MECHANICAL PROBLEMS ................................................................ 453 10.4.1 FLIGHT CLEARANCE AND HARD FACING ................................................ 454 10.4.2 BARREL AND SCREW ALIGNMENT ........................................................ 456 10.4.3 EXTRUDER BARREL SUPPORTS .............................................................. 457 10.4.4 FIRST-TIME INSTALLATION OF A SCREW ................................................ 459 10.4.5 SCREW BREAKS .................................................................................. 460 10.4.6 PROTECTION FROM HIGH-PRESSURE EVENTS ........................................ 462 10.4.7 GEARBOX LUBRICATING OIL ................................................................ 464 10.4.8 PARTICLE SEALS AND VISCOSEALS ........................................................ 464 10.4.9 SCREW CLEANING .............................................................................. 466 10.5 COMMON ELECTRICAL AND SENSOR PROBLEMS ................................................ 467 10.5.1 THERMOCOUPLES .............................................................................. 467 10.5.2 PRESSURE SENSORS .......................................................................... 467 10.5.3 ELECTRONIC FILTERS AND NOISE .......................................................... 469 10.6 MOTORS AND DRIVE SYSTEMS ........................................................................ 470 10.6.1 MOTOR EFFICIENCIES AND POWER FACTORS .......................................... 473 10.7 TYPICAL SCREW CHANNEL DIMENSIONS ........................................................ 474 10.8 COMMON CALCULATIONS ................................................................................ 474 10.8.1 ENERGY DISSIPATED BY THE SCREW .................................................. 475 10.8.2 SCREW GEOMETRY INDICES .............................................................. 476 10.9 BARREL TEMPERATURE OPTIMIZATION ............................................................ 477 10.10 SCREW TEMPERATURE PROFILE ........................................................................ 481 10.11 THE SCREW MANUFACTURING AND REFURBISHING PROCESS ............................ 490 10.12 INJECTION-MOLDING PLASTICATORS .................................................................. 498 10.12.1 CALCULATIONS FOR INJECTION-MOLDING PLASTICATORS .......................... 500 10.13 NEW EQUIPMENT INSTALLATIONS .................................................................... 500 10.13.1 CASE STUDY: A LARGE DIAMETER EXTRUDER PURCHASE .................... 504 10.13.2 CASE STUDY: EXTRUDER AND LINE PURCHASE FOR A NEW PRODUCT ... 505 10.13.3 A HIGH-DENSITY FOAMED SHEET PRODUCT ........................................ 506 10.13.4 SUMMARY FOR NEW EQUIPMENT INSTALLATIONS ................................ 508 NOMENCLATURE ...................................................................................................... 509 REFERENCES .............................................................................................................. 511 11 CONTAMINATION IN THE FINISHED PRODUCT ........................................ 515 11.1 FOREIGN CONTAMINANTS IN THE EXTRUDATE .................................................. 515 11.1.1 MELT FILTRATION ................................................................................ 516 11.1.2 METAL FRAGMENTS IN THE EXTRUDATE .............................................. 521 11.1.3 GAS BUBBLES IN A NEW SHEET LINE ................................................ 521 11.2 GELS IN POLYOLEFIN RESINS ........................................................................... 522 11.2.1 PROTOCOLS FOR GEL ANALYSIS ............................................................ 524 11.3 RESIN DECOMPOSITION IN STAGNANT REGIONS OF A PROCESS ........................ 529 11.3.1 TRANSFER LINES ............................................................................... 530 11.4 IMPROPER SHUTDOWN OF PROCESSING EQUIPMENT ........................................ 533 11.5 EQUIPMENT PURGING ................................................................................... 534 11.6 OXYGEN EXCLUSION AT THE HOPPER 536 11.7 FLIGHT RADII SIZE 537 11.8 DRYING THE RESIN ....................................................................................... 540 11.9 COLOR MASTERBATCHES ................................................................................. 541 11.10 CASE STUDIES FOR EXTRUSION PROCESSES WITH CONTAMINATION IN THE PRODUCT ....................................................................................................... 542 11.10.1 INTERMITTENT CROSSLINKED GELS IN A FILM PRODUCT ........................ 542 11.10.2 SMALL GELS IN AN LLDPE FILM PRODUCT .......................................... 548 11.10.3 DEGASSING HOLES IN BLOW-MOLDED BOTTLES .................................... 551 11.11 CONTAMINATION IN INJECTION-MOLDED PARTS ............................................... 554 11.11.1 SPLAY DEFECTS FOR INJECTION-MOLDED PARTS .................................... 554 11.12 INJECTION-MOLDING CASE STUDIES ............................................................... 557 11.12.1 INJECTION-MOLDED PARTS WITH SPLAY AND POOR RESIN COLOR PURGE 557 11.12.2 BLACK COLOR STREAKS IN MOLDED PARTS: CASE ONE ........................ 561 11.12.3 BLACK STREAKS IN MOLDED PARTS: CASE TWO .................................. 566 11.12.4 SILVER STREAKS IN A CLEAR GPPS RESIN INJECTION-MOLDED PACKAGING PART .............................................................................. 570 11.12.5 THE INJECTION-MOLDING PROBLEM AT SATURN .................................. 577 11.13 GELS CAUSED BY A POORLY DESIGNED TRANSFER LINE .................................... 578 11.14 THE INCUMBENT RESIN EFFECT ...................................................................... 580 NOMENCLATURE ...................................................................................................... 581 REFERENCES ............................................................................................................ 582 12 FLOW SURGING ............................................................................................ 585 12.1 AN OVERVIEW OF THE COMMON CAUSES FOR FLOW SURGING .......................... 586 12.1.1 RELATIONSHIP BETWEEN DISCHARGE PRESSURE AND RATE AT THE DIE 586 12.2 TROUBLESHOOTING FLOW SURGING PROCESSES ................................................ 587 12.3 BARREL ZONE AND SCREW TEMPERATURE CONTROL .......................................... 588 12.3.1 WATER- AND AIR-COOLED BARREL ZONES ............................................ 589 12.4 ROTATION- AND GEOMETRY-INDUCED PRESSURE OSCILLATIONS ........................ 590 12.5 GEAR PUMP CONTROL .................................................................................... 592 12.6 SOLIDS BLOCKING THE FLOW PATH .................................................................. 595 12.7 CASE STUDIES FOR EXTRUSION PROCESSES THAT FLOW SURGE .......................... 595 12.7.1 POOR BARREL ZONE TEMPERATURE CONTROL ........................................ 595 12.7.2 OPTIMIZATION OF BARREL TEMPERATURES FOR IMPROVED SOLIDS CONVEYING ...................................................................................... 598 12.7.3 FLOW SURGING DUE TO HIGH TEMPERATURES IN THE FEED SECTION OF THE SCREW .................................................................................... 600 12.7.4 FLOW SURGING DUE TO HIGH TEMPERATURES IN THE FEED CASING .. 607 12.7.5 FLOW SURGING DUE TO A POORLY DESIGNED BARRIER ENTRY FOR GPPS RESIN .................................................................................... 609 12.7.6 SOLID BLOCKAGE AT THE ENTRY OF A SPIRAL MIXER ............................ 612 12.7.7 FLOW SURGING CAUSED BY A WORN FEED CASING AND A NEW BARREL 618 12.7.8 FLOW SURGING FOR A PC RESIN EXTRUSION PROCESS ........................ 627 NOMENCLATURE ..................................................................................................... 631 REFERENCES ........................................................................................................... 632 13 RATE-LIMITED EXTRUSION PROCESSES .................................................. 635 13.1 VENT FLOW FOR MULTIPLE-STAGE EXTRUDERS ........................ 637 13.2 SCREW WEAR .................................................................................................. 639 13.3 HIGH-PERFORMANCE AND BARRIER SCREWS FOR IMPROVED RATES .................... 641 13.4 CASE STUDIES THAT WERE RATE LIMITED ..................................................... 641 13.4.1 RATE LIMITATION DUE TO A WORN SCREW .......................................... 641 13.4.2 RATE LIMITATION DUE TO SOLID POLYMER FRAGMENTS IN THE EXTRUDATE ........................................................................................ 642 13.4.3 RATE LIMITED BY THE DISCHARGE TEMPERATURE FOR A PELLETIZING EXTRUDER ........................................................................................ 647 13.4.4 LARGE DIAMETER EXTRUDER RUNNING PS RESIN ............................... 655 13.4.5 RATE LIMITED BY DISCHARGE TEMPERATURE AND TORQUE FOR STARCH EXTRUSION ....................................................................................... 658 13.4.6 VENT FLOW FOR A TWO-STAGE SCREW RUNNING A LOW BULK DENSITY PS FEEDSTOCK ................................................................................. 661 13.4.7 INCREASING THE RATE OF A LARGE PART BLOW-MOLDING PROCESS .... 664 NOMENCLATURE ...................................................................................................... 668 REFERENCES ................................... 668 14 BARRIER AND HIGH-PERFORMANCE SCREWS .......................................... 671 14.1 BARRIER SCREWS ........................................................................................... 673 14.2 WAVE DISPERSION SCREWS ........................................................................... 679 14.2.1 DOUBLE WAVE SCREW ....................................................................... 679 14.2.2 ENERGY TRANSFER SCREWS ............................................................... 681 14.2.3 VARIABLE BARRIER ENERGY TRANSFER SCREWS .................................... 687 14.2.4 DISTRIBUTIVE MELT MIXING SCREWS .................................................. 691 14.2.5 FUSION SCREWS ............................................................................... 695 14.3 OTHER HIGH-PERFORMANCE SCREW DESIGNS .................................................. 696 14.3.1 STRATABLEND SCREWS ....................................................................... 696 14.3.2 UNIMIX SCREWS ............................................................................. 698 14.4 CALCULATION OF THE SPECIFIC ROTATION RATE ................................................ 699 NOMENCLATURE ..................................................................................................... 700 REFERENCES ........................................................................................................... 700 15 MELT-FED EXTRUDERS ............................................................................... 703 15.1 SIMULATION METHODS ................................................................................... 703 15.2 COMPOUNDING PROCESSES ........................................................................... 704 15.2.1 COMMON PROBLEMS FOR MELT-FED EXTRUDERS ON COMPOUNDING LINES ............................................................................................... 707 15.3 LARGE-DIAMETER PUMPING EXTRUDERS ........................................................ 707 15.3.1 LOSS OF RATE DUE TO POOR MATERIAL CONVEYANCE IN THE FEED SECTION ................................................................................. 717 15.3.2 OPERATION OF THE SLIDE VALVE ........................................................ 719 15.3.3 NITROGEN INERTING ON VENT DOMES ................................................ 720 15.4 SECONDARY EXTRUDERS FOR TANDEM FOAM SHEET LINES .............................. 720 15.4.1 HIGH-PERFORMANCE COOLING SCREWS .............................................. 724 NOMENCLATURE ...................................................................................................... 728 REFERENCES ............................................................................................................ 728 APPENDIX A1 POLYMER ABBREVIATION DEFINITIONS .............................................................. 731 APPENDIX A3 RHEOLOGICAL CALCULATIONS FOR A CAPILLARY RHEOMETER AND FOR A CONE AND PLATE RHEOMETER ...................................................................... 733 A3.1 CAPILLARY RHEOMETER .................................................................................. 733 A3.2 CONE AND PLATE RHEOMETER ........................................................................ 737 REFERENCES ............................................................................................................ 739 APPENDIX A4 SHEAR STRESS AT A SLIDING INTERFACE AND MELTING FLUXES FOR SELECT RESINS .................................................................................................... 741 A4.1 SHEAR STRESS AT A SLIDING INTERFACE FOR SELECT RESINS .............................. 741 A4.2 MELTING FLUXES FOR SELECT RESINS .............................................................. 745 REFERENCES ............................................................................................................ 748 APPENDIX A5 SOLIDS CONVEYING MODEL DERIVATIONS AND THE COMPLETE LDPE SOLIDS CONVEYING DATA SET ................................................................ 751 A5.1 CHANNEL DIMENSIONS, ASSUMPTIONS, AND BASIC FORCE BALANCES ............ 751 A5.2 CAMPBELL-DONTULA MODEL ............................................................................ 753 A5.2.1 MODIFIED CAMPBELL-DONTULA MODEL .............................................. 754 A5.3 HYUN-SPALDING MODEL ................................................................................ 756 A5.4 YAMAMURO-PENUMADU-CAMPBELL MODEL .................................................. 758 A5.5 CAMPBELL-SPALDING MODEL .......................................................................... 760 A5.6 THE COMPLETE DOW SOLIDS CONVEYING DATA SET ........................................ 760 REFERENCES ........................................................................................................... 765 APPENDIX A6 MELTING RATE MODEL DEVELOPMENT ............................................................. 767 A6.1 DERIVATION OF THE MELTING PERFORMANCE EQUATIONS FOR A CONVENTIONAL CHANNEL .............................................................................................. 767 A6.2 EFFECT OF STATIC PRESSURE ON MELTING ........................................................... 778 REFERENCES ............................................................................................................ 778 APPENDIX A7 FLOW AND ENERGY EQUATION DEVELOPMENT FOR THE METERING CHANNEL 779 A7.1 TRANSFORMED FRAME FLOW ANALYSIS ............................................................ 779 A7.1.1 X-DIRECTIONAL FLOW ......................................................................... 781 A7.1.2 Z-DIRECTIONAL FLOW ......................................................................... 782 A7.1.3 Z-DIRECTIONAL FLOW FOR HELIX ROTATION WITH A STATIONARY SCREW CORE AND BARREL ..................................................... 788 A7.1.4 2-DIRECTIONAL FLOW DUE TO A PRESSURE GRADIENT .......................... 790 A7.2 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION ...................................... 795 A7.2.1 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION: GENERALIZED SOLUTION ......................................................................................... 795 A7.2.2 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION FOR CHANNELS WITH SMALL ASPECT RATIOS (H/W 0.1) ............................. 801 A7.3 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION ...................................... 803 A7.3.1 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION: GENERALIZED SOLUTION ......................................................................................... 804 A7.3.2 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION FOR CHANNELS WITH SMALL ASPECT RATIOS (H/W 0.1) .................... 807 REFERENCES ........................................................................................................... 808 AUTHOR INDEX ..................................................................................................... 809 SUBJECT INDEX ...................................................................................................... 817
adam_txt	CONTENTS PREFACE . V ACKNOWLEDGEMENTS . VII 1 SINGLE-SCREW EXTRUSION: INTRODUCTION AND TROUBLESHOOTING . 1 1.1 ORGANIZATION OF THIS BOOK . 3 1.2 TROUBLESHOOTING EXTRUSION PROCESSES . 5 1.2.1 THE INJECTION MOLDING PROBLEM AT SATURN . 5 1.3 INTRODUCTION TO SCREW GEOMETRY . 6 1.3.1 SCREW GEOMETRIC QUANTITATIVE CHARACTERISTICS . 8 1.4 SIMPLE FLOW EQUATIONS FOR THE METERING SECTION . 11 1.5 EXAMPLE CALCULATIONS . 15 1.5.1 EXAMPLE 1: CALCULATION OF ROTATIONAL AND PRESSURE FLOW COMPONENTS . 15 1.5.2 EXAMPLE 2: FLOW CALCULATIONS FOR A PROPERLY OPERATING EXTRUDER . 18 1.5.3 EXAMPLE 3: FLOW CALCULATIONS FOR AN IMPROPERLY OPERATING EXTRUDER . 18 1.5.4 METERING CHANNEL CALCULATION SUMMARY . 20 NOMENCLATURE . 20 REFERENCES . 22 2 POLYMER MATERIALS . 23 2.1 INTRODUCTION AND HISTORY . 24 2.1.1 HISTORY OF NATURAL POLYMERS . 25 2.1.2 THE HISTORY OF SYNTHETIC POLYMERS . 26 2.2 CHARACTERISTICS OF SYNTHETIC POLYMERS . 28 2.3 STRUCTURE EFFECTS ON PROPERTIES . 31 2.3.1 STEREOCHEMISTRY . 34 2.3.2 MELTING AND GLASS TRANSITION TEMPERATURES . 35 2.3.3 CRYSTALLINITY . 37 2.4 POLYMER PRODUCTION AND REACTION ENGINEERING . 40 2.4.1 CONDENSATION REACTIONS . 40 2.4.2 ADDITION REACTIONS . 43 2.5 POLYMER DEGRADATION . 46 2.5.1 CEILING TEMPERATURE . 49 2.5.2 DEGRADATION OF VINYL POLYMERS . 51 2.5.3 DEGRADATION OF CONDENSATION POLYMERS . 53 REFERENCES . 54 3 INTRODUCTION TO POLYMER RHEOLOGY FOR EXTRUSION . 57 3.1 INTRODUCTION TO THE DEFORMATION OF MATERIALS . 57 3.2 INTRODUCTION TO BASIC CONCEPTS OF MOLECULAR SIZE . 58 3.2.1 SIZE DISTRIBUTION EXAMPLE . 59 3.2.2 MOLECULAR WEIGHT DISTRIBUTIONS FOR POLYMERS . 60 3.3 BASIC RHEOLOGY CONCEPTS . 63 3.4 POLYMER SOLUTION VISCOSITY AND POLYMER MOLECULAR WEIGHT . 68 3.4.1 SAMPLE CALCULATION OF SOLUTION VISCOSITY . 71 3.5 INTRODUCTION TO VISCOELASTICITY . 72 3.6 MEASUREMENT OF POLYMER VISCOSITY . 80 3.6.1 CAPILLARY RHEOMETERS . 81 3.6.2 CONE AND PLATE RHEOMETERS . 91 3.6.3 MELT INDEX AND MELT FLOW RATE . 95 3.7 VISCOSITY OF POLYMERS AS FUNCTIONS OF MOLECULAR CHARACTER, TEMPERATURE, AND PRESSURE . 98 3.8 HISTORICAL MODELS FOR NON-NEWTONIAN FLOW . 103 3.9 POWER LAW AND VISCOSITY SHEAR RATE DEPENDENCE . 105 3.9.1 SHEAR STRESS FROM NEWTONIAN TO INFINITE SHEAR . 105 3.9.2 VISCOSITY AS A FUNCTION OF SHEAR RATE . 106 3.9.3 THE POWER LAW AND PROCESS DISSIPATION . 107 3.9.4 VISCOSITY, SHEAR RATE, AND DISSIPATION . 107 3.9.5 PERCOLATION IN STRUCTURED SYSTEMS . 110 3.9.6 TUBE FLOW DATA AND DATA ANALYSIS . 110 3.9.7 DISPERSION BASED POWER LAW CONSTANT N . 112 3.9.8 RHEOLOGICAL IMPLICTIONS FOR EXTRUSION AND MOLDING PROCESSES 126 NOMENCLATURE . 130 REFERENCES . 133 4 RESIN PHYSICAL PROPERTIES RELATED TO PROCESSING . 137 4.1 BULK DENSITY AND COMPACTION . 138 4.1.1 MEASUREMENT OF BULK DENSITY . 139 4.1.2 MEASURING THE COMPACTION CHARACTERISTICS OF A RESIN . 140 4.2 LATERAL STRESS RATIO * . 143 4.2.1 MEASURING THE LATERAL STRESS RATIO . 144 4.3 STRESS AT A SLIDING INTERFACE . 146 4.3.1 THE SCREW SIMULATOR AND THE MEASUREMENT OF THE STRESS AT THE INTERFACE . 147 4.4 MELTING FLUX . 149 4.5 HEAT CAPACITY . 151 4.6 THERMAL CONDUCTIVITY AND HEAT TRANSFER . 153 4.7 MELT DENSITY . 154 NOMENCLATURE . 156 REFERENCES . 156 5 SOLIDS CONVEYING . 159 5.1 DESCRIPTION OF THE SOLIDS CONVEYING PROCESS . 160 5.2 LITERATURE REVIEW OF SMOOTH-BORE SOLIDS CONVEYING MODELS . 162 5.2.1 DARNELL AND MOL MODEL . 165 5.2.2 TADMOR AND KLEIN MODEL . 166 5.2.3 CLARKSON UNIVERSITY MODELS . 167 5.2.4 HYUN AND SPALDING MODEL . 170 5.2.5 MOYSEY AND THOMPSON MODEL . 171 5.3 MODERN EXPERIMENTAL SOLIDS CONVEYING DEVICES . 171 5.3.1 SOLIDS CONVEYING DEVICES AT CLARKSON UNIVERSITY . 172 5.3.2 THE SOLIDS CONVEYING DEVICE AT DOW . 186 5.4 COMPARISON OF THE MODIFIED CAMPBELL-DONTULA MODEL WITH EXPERIMENTAL DATA . 196 5.4.1 SOLIDS CONVEYING EXAMPLE CALCULATION . 200 5.5 GROOVED BORE SOLIDS CONVEYING . 202 5.5.1 GROOVED BARREL SOLIDS CONVEYING MODELS . 206 5.6 SOLIDS CONVEYING NOTES . 208 NOMENCLATURE . 211 REFERENCES . 213 6 THE MELTING PROCESS . 217 6.1 COMPRESSION RATIO AND COMPRESSION RATE . 219 6.2 THE MELTING PROCESS . 221 6.2.1 THE MELTING PROCESS AS A FUNCTION OF SCREW GEOMETRY . 222 6.2.2 REVIEW OF THE CLASSICAL LITERATURE . 227 6.2.3 REEVALUATION OF THE TADMOR AND KLEIN MELTING DATA . 228 6.3 THEORY DEVELOPMENT FOR MELTING USING SCREW ROTATION PHYSICS . 231 6.3.1 MELTING MODEL FOR A CONVENTIONAL TRANSITION SECTION USING SCREW ROTATION PHYSICS . 232 6.3.2 MELTING MODELS FOR BARRIER SCREW SECTIONS . 246 6.4 EFFECT OF PRESSURE ON MELTING RATE . 255 6.5 ONE-DIMENSIONAL MELTING . 256 6.5.1 ONE-DIMENSIONAL MELTING MODEL . 260 6.6 SOLID BED BREAKUP . 262 6.7 MELTING SECTION CHARACTERISTICS . 266 NOMENCLATURE . 268 REFERENCES . 270 7 FLUID FLOW IN METERING CHANNELS . 275 7.1 INTRODUCTION TO THE REFERENCE FRAME . 275 7.2 LABORATORY OBSERVATIONS . 278 7.3 LITERATURE SURVEY . 282 7.4 DEVELOPMENT OF LINEARIZED FLOW ANALYSIS . 287 7.4.1 EXAMPLE FLOW CALCULATION . 303 7.5 NUMERICAL FLOW EVALUATION . 306 7.5.1 SIMULATION OF A 500 MM DIAMETER MELT-FED EXTRUDER . 308 7.5.2 EXTRUSION VARIABLES AND ERRORS . 310 7.5.3 CORRECTIONS TO ROTATIONAL FLOW . 316 7.5.4 SIMULATION OF THE 500 MM DIAMETER EXTRUDER USING F C . 321 7.6 FRAME DEPENDENT VARIABLES . 322 7.6.1 EXAMPLE CALCULATION OF ENERGY DISSIPATION . 325 7.7 VISCOUS ENERGY DISSIPATION AND TEMPERATURE OF THE RESIN IN THE CHANNEL . 326 7.7.1 ENERGY DISSIPATION AND CHANNEL TEMPERATURE FOR SCREW ROTATION . 332 7.7.2 ENERGY DISSIPATION AND CHANNEL TEMPERATURE FOR BARREL ROTATION . 336 7.7.3 TEMPERATURE INCREASE CALCULATION EXAMPLE FOR A SCREW PUMP 337 7.7.4 HEAT TRANSFER COEFFICIENTS . 342 7.7.5 TEMPERATURE CALCULATION USING A CONTROL VOLUME TECHNIQUE . 343 7.7.6 NUMERICAL COMPARISON OF TEMPERATURES FOR SCREW AND BARREL ROTATIONS . 346 7.8 METERING SECTION CHARACTERISTICS . 348 NOMENCLATURE . 350 REFERENCES . 354 8 MIXING PROCESSES FOR SINGLE-SCREW EXTRUDERS . 359 8.1 COMMON MIXING OPERATIONS FOR SINGLE-SCREW EXTRUDERS . 360 8.1.1 COMMON MIXING APPLICATIONS . 361 8.2 DISPERSIVE AND DISTRIBUTIVE MIXING PROCESSES . 363 8.3 FUNDAMENTALS OF MIXING . 365 8.3.1 MEASURES OF MIXING . 366 8.3.2 EXPERIMENTAL DEMONSTRATION OF MIXING . 368 8.4 THE MELTING PROCESS AS THE PRIMARY MECHANISM FOR MIXING . 376 8.4.1 EXPERIMENTAL ANALYSIS OF THE MELTING AND MIXING CAPACITY OF A SCREW . 379 8.4.2 MIXING AND BARRIER-FLIGHTED MELTING SECTIONS . 382 8.5 SECONDARY MIXING PROCESSES AND DEVICES . 383 8.5.1 MADDOCK-STYLE MIXERS . 384 8.5.2 BLISTER RING MIXERS . 393 8.5.3 SPIRAL DAM MIXERS . 395 8.5.4 PIN-TYPE MIXERS . 396 8.5.5 KNOB MIXERS . 397 8.5.6 GEAR MIXERS . 398 8.5.7 DYNAMIC MIXERS . 399 8.5.8 STATIC MIXERS . 401 8.6 MIXING USING NATURAL RESINS AND MASTERBATCHES . 408 8.7 MIXING AND MELTING PERFORMANCE AS A FUNCTION OF FLIGHT CLEARANCE . 409 8.8 HIGH PRESSURES DURING MELTING AND AGGLOMERATES . 410 8.9 EFFECT OF DISCHARGE PRESSURE ON MIXING . 410 8.10 SHEAR REFINEMENT . 411 8.11 DIRECT COMPOUNDING USING SINGLE-SCREW EXTRUDERS . 413 NOMENCLATURE . 414 REFERENCES . 416 9 SCALING OF SINGLE-SCREW EXTRUSION PROCESSES . 421 9.1 SCALING RULES . 422 9.2 ENGINEERING DESIGN METHOD FOR PLASTICATING SCREWS . 423 9.2.1 PROCESS ANALYSIS AND SIMULATIONS . 427 9.3 SCALE-UP FROM A 40 MM DIAMETER EXTRUDER TO AN 80 MM DIAMETER MACHINE FOR A PE RESIN . 427 9.4 RATE INCREASE FOR AN 88.9 MM DIAMETER EXTRUDER RUNNING A HIPS RESIN 431 NOMENCLATURE . 438 REFERENCES . 439 10 INTRODUCTION TO TROUBLESHOOTING THE EXTRUSION PROCESS . 441 10.1 THE TROUBLESHOOTING PROCESS . 442 10.2 HYPOTHESIS SETTING AND PROBLEM SOLVING . 445 10.2.1 CASE STUDY FOR THE DESIGN OF A NEW RESIN . 446 10.2.2 CASE STUDY FOR A SURFACE BLEMISH . 448 10.2.3 CASE STUDY FOR A PROFILE EXTRUSION PROCESS . 449 10.3 EQUIPMENT AND TOOLS NEEDED FOR TROUBLESHOOTING . 450 10.3.1 MADDOCK SOLIDIFICATION EXPERIMENT . 452 10.4 COMMON MECHANICAL PROBLEMS . 453 10.4.1 FLIGHT CLEARANCE AND HARD FACING . 454 10.4.2 BARREL AND SCREW ALIGNMENT . 456 10.4.3 EXTRUDER BARREL SUPPORTS . 457 10.4.4 FIRST-TIME INSTALLATION OF A SCREW . 459 10.4.5 SCREW BREAKS . 460 10.4.6 PROTECTION FROM HIGH-PRESSURE EVENTS . 462 10.4.7 GEARBOX LUBRICATING OIL . 464 10.4.8 PARTICLE SEALS AND VISCOSEALS . 464 10.4.9 SCREW CLEANING . 466 10.5 COMMON ELECTRICAL AND SENSOR PROBLEMS . 467 10.5.1 THERMOCOUPLES . 467 10.5.2 PRESSURE SENSORS . 467 10.5.3 ELECTRONIC FILTERS AND NOISE . 469 10.6 MOTORS AND DRIVE SYSTEMS . 470 10.6.1 MOTOR EFFICIENCIES AND POWER FACTORS . 473 10.7 TYPICAL SCREW CHANNEL DIMENSIONS . 474 10.8 COMMON CALCULATIONS . 474 10.8.1 ENERGY DISSIPATED BY THE SCREW . 475 10.8.2 SCREW GEOMETRY INDICES . 476 10.9 BARREL TEMPERATURE OPTIMIZATION . 477 10.10 SCREW TEMPERATURE PROFILE . 481 10.11 THE SCREW MANUFACTURING AND REFURBISHING PROCESS . 490 10.12 INJECTION-MOLDING PLASTICATORS . 498 10.12.1 CALCULATIONS FOR INJECTION-MOLDING PLASTICATORS . 500 10.13 NEW EQUIPMENT INSTALLATIONS . 500 10.13.1 CASE STUDY: A LARGE DIAMETER EXTRUDER PURCHASE . 504 10.13.2 CASE STUDY: EXTRUDER AND LINE PURCHASE FOR A NEW PRODUCT . 505 10.13.3 A HIGH-DENSITY FOAMED SHEET PRODUCT . 506 10.13.4 SUMMARY FOR NEW EQUIPMENT INSTALLATIONS . 508 NOMENCLATURE . 509 REFERENCES . 511 11 CONTAMINATION IN THE FINISHED PRODUCT . 515 11.1 FOREIGN CONTAMINANTS IN THE EXTRUDATE . 515 11.1.1 MELT FILTRATION . 516 11.1.2 METAL FRAGMENTS IN THE EXTRUDATE . 521 11.1.3 GAS BUBBLES IN A NEW SHEET LINE . 521 11.2 GELS IN POLYOLEFIN RESINS . 522 11.2.1 PROTOCOLS FOR GEL ANALYSIS . 524 11.3 RESIN DECOMPOSITION IN STAGNANT REGIONS OF A PROCESS . 529 11.3.1 TRANSFER LINES . 530 11.4 IMPROPER SHUTDOWN OF PROCESSING EQUIPMENT . 533 11.5 EQUIPMENT PURGING . 534 11.6 OXYGEN EXCLUSION AT THE HOPPER 536 11.7 FLIGHT RADII SIZE 537 11.8 DRYING THE RESIN . 540 11.9 COLOR MASTERBATCHES . 541 11.10 CASE STUDIES FOR EXTRUSION PROCESSES WITH CONTAMINATION IN THE PRODUCT . 542 11.10.1 INTERMITTENT CROSSLINKED GELS IN A FILM PRODUCT . 542 11.10.2 SMALL GELS IN AN LLDPE FILM PRODUCT . 548 11.10.3 DEGASSING HOLES IN BLOW-MOLDED BOTTLES . 551 11.11 CONTAMINATION IN INJECTION-MOLDED PARTS . 554 11.11.1 SPLAY DEFECTS FOR INJECTION-MOLDED PARTS . 554 11.12 INJECTION-MOLDING CASE STUDIES . 557 11.12.1 INJECTION-MOLDED PARTS WITH SPLAY AND POOR RESIN COLOR PURGE 557 11.12.2 BLACK COLOR STREAKS IN MOLDED PARTS: CASE ONE . 561 11.12.3 BLACK STREAKS IN MOLDED PARTS: CASE TWO . 566 11.12.4 SILVER STREAKS IN A CLEAR GPPS RESIN INJECTION-MOLDED PACKAGING PART . 570 11.12.5 THE INJECTION-MOLDING PROBLEM AT SATURN . 577 11.13 GELS CAUSED BY A POORLY DESIGNED TRANSFER LINE . 578 11.14 THE INCUMBENT RESIN EFFECT . 580 NOMENCLATURE . 581 REFERENCES . 582 12 FLOW SURGING . 585 12.1 AN OVERVIEW OF THE COMMON CAUSES FOR FLOW SURGING . 586 12.1.1 RELATIONSHIP BETWEEN DISCHARGE PRESSURE AND RATE AT THE DIE 586 12.2 TROUBLESHOOTING FLOW SURGING PROCESSES . 587 12.3 BARREL ZONE AND SCREW TEMPERATURE CONTROL . 588 12.3.1 WATER- AND AIR-COOLED BARREL ZONES . 589 12.4 ROTATION- AND GEOMETRY-INDUCED PRESSURE OSCILLATIONS . 590 12.5 GEAR PUMP CONTROL . 592 12.6 SOLIDS BLOCKING THE FLOW PATH . 595 12.7 CASE STUDIES FOR EXTRUSION PROCESSES THAT FLOW SURGE . 595 12.7.1 POOR BARREL ZONE TEMPERATURE CONTROL . 595 12.7.2 OPTIMIZATION OF BARREL TEMPERATURES FOR IMPROVED SOLIDS CONVEYING . 598 12.7.3 FLOW SURGING DUE TO HIGH TEMPERATURES IN THE FEED SECTION OF THE SCREW . 600 12.7.4 FLOW SURGING DUE TO HIGH TEMPERATURES IN THE FEED CASING . 607 12.7.5 FLOW SURGING DUE TO A POORLY DESIGNED BARRIER ENTRY FOR GPPS RESIN . 609 12.7.6 SOLID BLOCKAGE AT THE ENTRY OF A SPIRAL MIXER . 612 12.7.7 FLOW SURGING CAUSED BY A WORN FEED CASING AND A NEW BARREL 618 12.7.8 FLOW SURGING FOR A PC RESIN EXTRUSION PROCESS . 627 NOMENCLATURE . 631 REFERENCES . 632 13 RATE-LIMITED EXTRUSION PROCESSES . 635 13.1 VENT FLOW FOR MULTIPLE-STAGE EXTRUDERS . 637 13.2 SCREW WEAR . 639 13.3 HIGH-PERFORMANCE AND BARRIER SCREWS FOR IMPROVED RATES . 641 13.4 CASE STUDIES THAT WERE RATE LIMITED . 641 13.4.1 RATE LIMITATION DUE TO A WORN SCREW . 641 13.4.2 RATE LIMITATION DUE TO SOLID POLYMER FRAGMENTS IN THE EXTRUDATE . 642 13.4.3 RATE LIMITED BY THE DISCHARGE TEMPERATURE FOR A PELLETIZING EXTRUDER . 647 13.4.4 LARGE DIAMETER EXTRUDER RUNNING PS RESIN . 655 13.4.5 RATE LIMITED BY DISCHARGE TEMPERATURE AND TORQUE FOR STARCH EXTRUSION . 658 13.4.6 VENT FLOW FOR A TWO-STAGE SCREW RUNNING A LOW BULK DENSITY PS FEEDSTOCK . 661 13.4.7 INCREASING THE RATE OF A LARGE PART BLOW-MOLDING PROCESS . 664 NOMENCLATURE . 668 REFERENCES . 668 14 BARRIER AND HIGH-PERFORMANCE SCREWS . 671 14.1 BARRIER SCREWS . 673 14.2 WAVE DISPERSION SCREWS . 679 14.2.1 DOUBLE WAVE SCREW . 679 14.2.2 ENERGY TRANSFER SCREWS . 681 14.2.3 VARIABLE BARRIER ENERGY TRANSFER SCREWS . 687 14.2.4 DISTRIBUTIVE MELT MIXING SCREWS . 691 14.2.5 FUSION SCREWS . 695 14.3 OTHER HIGH-PERFORMANCE SCREW DESIGNS . 696 14.3.1 STRATABLEND SCREWS . 696 14.3.2 UNIMIX SCREWS . 698 14.4 CALCULATION OF THE SPECIFIC ROTATION RATE . 699 NOMENCLATURE . 700 REFERENCES . 700 15 MELT-FED EXTRUDERS . 703 15.1 SIMULATION METHODS . 703 15.2 COMPOUNDING PROCESSES . 704 15.2.1 COMMON PROBLEMS FOR MELT-FED EXTRUDERS ON COMPOUNDING LINES . 707 15.3 LARGE-DIAMETER PUMPING EXTRUDERS . 707 15.3.1 LOSS OF RATE DUE TO POOR MATERIAL CONVEYANCE IN THE FEED SECTION . 717 15.3.2 OPERATION OF THE SLIDE VALVE . 719 15.3.3 NITROGEN INERTING ON VENT DOMES . 720 15.4 SECONDARY EXTRUDERS FOR TANDEM FOAM SHEET LINES . 720 15.4.1 HIGH-PERFORMANCE COOLING SCREWS . 724 NOMENCLATURE . 728 REFERENCES . 728 APPENDIX A1 POLYMER ABBREVIATION DEFINITIONS . 731 APPENDIX A3 RHEOLOGICAL CALCULATIONS FOR A CAPILLARY RHEOMETER AND FOR A CONE AND PLATE RHEOMETER . 733 A3.1 CAPILLARY RHEOMETER . 733 A3.2 CONE AND PLATE RHEOMETER . 737 REFERENCES . 739 APPENDIX A4 SHEAR STRESS AT A SLIDING INTERFACE AND MELTING FLUXES FOR SELECT RESINS . 741 A4.1 SHEAR STRESS AT A SLIDING INTERFACE FOR SELECT RESINS . 741 A4.2 MELTING FLUXES FOR SELECT RESINS . 745 REFERENCES . 748 APPENDIX A5 SOLIDS CONVEYING MODEL DERIVATIONS AND THE COMPLETE LDPE SOLIDS CONVEYING DATA SET . 751 A5.1 CHANNEL DIMENSIONS, ASSUMPTIONS, AND BASIC FORCE BALANCES . 751 A5.2 CAMPBELL-DONTULA MODEL . 753 A5.2.1 MODIFIED CAMPBELL-DONTULA MODEL . 754 A5.3 HYUN-SPALDING MODEL . 756 A5.4 YAMAMURO-PENUMADU-CAMPBELL MODEL . 758 A5.5 CAMPBELL-SPALDING MODEL . 760 A5.6 THE COMPLETE DOW SOLIDS CONVEYING DATA SET . 760 REFERENCES . 765 APPENDIX A6 MELTING RATE MODEL DEVELOPMENT . 767 A6.1 DERIVATION OF THE MELTING PERFORMANCE EQUATIONS FOR A CONVENTIONAL CHANNEL . 767 A6.2 EFFECT OF STATIC PRESSURE ON MELTING . 778 REFERENCES . 778 APPENDIX A7 FLOW AND ENERGY EQUATION DEVELOPMENT FOR THE METERING CHANNEL 779 A7.1 TRANSFORMED FRAME FLOW ANALYSIS . 779 A7.1.1 X-DIRECTIONAL FLOW . 781 A7.1.2 Z-DIRECTIONAL FLOW . 782 A7.1.3 Z-DIRECTIONAL FLOW FOR HELIX ROTATION WITH A STATIONARY SCREW CORE AND BARREL . 788 A7.1.4 2-DIRECTIONAL FLOW DUE TO A PRESSURE GRADIENT . 790 A7.2 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION . 795 A7.2.1 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION: GENERALIZED SOLUTION . 795 A7.2.2 VISCOUS ENERGY DISSIPATION FOR SCREW ROTATION FOR CHANNELS WITH SMALL ASPECT RATIOS (H/W 0.1) . 801 A7.3 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION . 803 A7.3.1 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION: GENERALIZED SOLUTION . 804 A7.3.2 VISCOUS ENERGY DISSIPATION FOR BARREL ROTATION FOR CHANNELS WITH SMALL ASPECT RATIOS (H/W 0.1) . 807 REFERENCES . 808 AUTHOR INDEX . 809 SUBJECT INDEX . 817
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author	Campbell, Gregory A. Spalding, Mark A.
author_GND	(DE-588)1225314119 (DE-588)120636758X
author_facet	Campbell, Gregory A. Spalding, Mark A.
author_role	aut aut
author_sort	Campbell, Gregory A.
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building	Verbundindex
bvnumber	BV047065300
classification_rvk	ZM 8165
classification_tum	CIT 740f
ctrlnum	(OCoLC)1237114738 (DE-599)DNB1210292696
discipline	Chemie / Pharmazie Werkstoffwissenschaften Chemie-Ingenieurwesen Werkstoffwissenschaften / Fertigungstechnik
discipline_str_mv	Chemie / Pharmazie Werkstoffwissenschaften Chemie-Ingenieurwesen Werkstoffwissenschaften / Fertigungstechnik
edition	2nd Edition
format	Book
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language	English
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physical	XIX, 825 Seiten Illustrationen, Diagramme 25 cm
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spelling	Campbell, Gregory A. Verfasser (DE-588)1225314119 aut Analyzing and troubleshooting single-screw extruders Gregory A. Campbell, Mark A. Spalding 2nd Edition Cincinnati, Ohio Hanser Publications [2021] München Hanser Publishers [2021] © 2021 XIX, 825 Seiten Illustrationen, Diagramme 25 cm txt rdacontent n rdamedia nc rdacarrier Fehlersuche (DE-588)4016615-6 gnd rswk-swf Einschneckenextruder (DE-588)4151391-5 gnd rswk-swf Extrudieren (DE-588)4071089-0 gnd rswk-swf Extrusion Kunststoffe Kunststoffverarbeitung FBKTEXTR: Extrudieren PLAS2020 Extrudieren (DE-588)4071089-0 s Einschneckenextruder (DE-588)4151391-5 s Fehlersuche (DE-588)4016615-6 s DE-604 Spalding, Mark A. Verfasser (DE-588)120636758X aut Hanser Publications (DE-588)1064064051 pbl Erscheint auch als Online-Ausgabe 9781569907856 DNB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=032472406&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis
spellingShingle	Campbell, Gregory A. Spalding, Mark A. Analyzing and troubleshooting single-screw extruders Fehlersuche (DE-588)4016615-6 gnd Einschneckenextruder (DE-588)4151391-5 gnd Extrudieren (DE-588)4071089-0 gnd
subject_GND	(DE-588)4016615-6 (DE-588)4151391-5 (DE-588)4071089-0
title	Analyzing and troubleshooting single-screw extruders
title_auth	Analyzing and troubleshooting single-screw extruders
title_exact_search	Analyzing and troubleshooting single-screw extruders
title_exact_search_txtP	Analyzing and troubleshooting single-screw extruders
title_full	Analyzing and troubleshooting single-screw extruders Gregory A. Campbell, Mark A. Spalding
title_fullStr	Analyzing and troubleshooting single-screw extruders Gregory A. Campbell, Mark A. Spalding
title_full_unstemmed	Analyzing and troubleshooting single-screw extruders Gregory A. Campbell, Mark A. Spalding
title_short	Analyzing and troubleshooting single-screw extruders
title_sort	analyzing and troubleshooting single screw extruders
topic	Fehlersuche (DE-588)4016615-6 gnd Einschneckenextruder (DE-588)4151391-5 gnd Extrudieren (DE-588)4071089-0 gnd
topic_facet	Fehlersuche Einschneckenextruder Extrudieren
url	http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=032472406&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
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