Extrusion Die Design and Process Control for Dimensional Stability

Extrusion Process and Die Design Consideration
for Extrudate Dimension Control
We Deliver Performance TM 0
Outline
• Rubber Compound Extrusion Operation
• Shear Viscosity and Die Swell of Rubber Compound
• Factors Affect Extruded Profile Size and Shape Change
• How to Use Die Swell Lab Data for Die Plate Design
• Profile Dimension Control through Process Control
• Summary
Rubber Compound Extrusion Operation
• Triplex Extruder
- Extruder
- Preform
- Die Plate
We Deliver Performance TM
Extruder Thought-put
Extruder through-put
Q = Qd (Drag flow) + Qp (Pressure flow)
D x H3 P
= ad x (Ns x D2 x H) – ap x ( )
Viscosity L
= fd (Screw Speed, Screw diameter, Screw flight height) – fp (Head Pressure, Viscosity, Screw diameter, Screw flight height)
For the same extruder, through-put is decided by Screw speed, Head pressure, and Viscosity.
Screw Speed Effect on Extrudate Temperature
Screw Speed and Head Pressure Effect on Extrudate Temperature
Head Pressure
Screw Speed and Head Pressure Effect on Through-put
• Through-put increases with

increasing Screw Speed
• Through-put decreases with

increasing Head Pressure
• Stock temperature increases

increasing Head Pressure
60 rpm
• For the same Die, Head Pressure
increases with increasing
Screw Speed 40 rpm
20 rpm
8147
1600.00 口金020
1400.00 口金030
口金040 口金073
質量流率 (g/s)
1200.00
60 rpm
1000.00
800.00
40 rpm
600.00
400.00
20 rpm
200.00
0.00
0.00E+00 2.00E+07 4.00E+07 6.00E+07 8.00E+07 1.00E+08 1.20E+08
押出頭壓力 (Pa)
Shear Viscosity and Die Swell of Rubber Compound
Shear Rate Range for Rubber Processing
Mooney viscosity
measured at 2 (1/s)
Viscosity
Viscosity : characterizing resistance to flow of liquids
Capillary Rheometer
Pe
Po
P = Pe - Po
Q : Volume metric flow rate
Correction Factors
• Rabinowitsch Correction for Non-Newtonian Fluid
• Bagley’s Correction for End Effect
Slit Rheometer
Pe Po
.
Shear Stress
Wall Shear Stress P = Pe - Po
Q : Volume metric flow rate
Newtonian case
Wall Shear Rate
Viscosity
Non- Newtonian case
Correction for the real wall shear rate is analogous to the Rabinowitch correction.
Wall Shear Rate
Viscosity
Normal stress difference (related Die Swell)

(The normal stress difference N1 can be determined from the exit pressure Pe.
Comparison of First Normal Stress Difference Values from Slit Rheometer Exit Pressure
Molecular Weight Effect on Viscosity
• Average Molecular Weight (MW): Higher MW, Higher Viscosity in Newtonian region
• Molecular Weight Distribution: Narrow MWD has steeper slope in the Power-law region
Power-law region
Typical Shear Viscosity of Rubber Compound
Power –law Model
Power –law Model
黏度-毛细管口金(L/D=20)
1.E+04 1.E+04
#8155 80 #8147 80
100 100
viscosity (poise)
Viscosity (poise)
120 120
1.E+03 1.E+03
1.E+02
10 100 1000 10000 1.E+02
10 100 1000 10000
剪力率值
剪力率值
y= 222159*exp(-0.0048T)*r(-0.7183) y = 1031567*exp(-0.0085T)*r(-0.7471)
R² = 0.996 R² = 0.994
小结:根据数据显示，同温度下，剪力率越高胶料黏度越低；同剪力率下，温度越
高胶料黏度越低
Capillary and Slit Rheometers Die Swell
DE
L
DE
DE
Extrudate Swell after exiting the Die diminishes as the Die is made longer.
Die swell is a viscoelastic memory effect from the flow contraction at the entrance to the die.
Capillary Die Swell
Capillary Die Swell
1
2.5
20
Die Swell from Three Different Capillary Dies.

Die Swell Ratio, from Capillary Rheometer, is as
Functions of Wall Shear Rate and Wall Shear Stress.
Die Swell as Function of L/D ratio and Shear Rate
Die plate region
Die Swell in a Slit Die
L
H
Slit Die
Die Swell in a Slit Die
Die Swell and Share Viscosity
Measurement Development at CSTC
實驗人員:馮輝詮、顏邦岳、葉全勛
Slit Dies from MTC
020 030
040 073
Slit Dies with different L/H Ratios
口金 ID 口金高度口金深度 Lo/Ho
Ho (mm) Lo (mm)
020 0.7 (mm) 4.5 (mm) 6.42
030 0.9 4.5 5
040 1.35 5 3.7
073 2 2.75 1.38
膨胀率-H/H0
8147 8155
y = -0.1191x + 2.1249
y = -0.1373x + 2.1813
2.20 R² = 0.9583 2.20
R² = 0.9748
2.00 2.00
H/H0(@r≒100)
H/H0(@r≒100)
1.80 1.80
1.60 1.60
1.40 1.40
1.20 1.20
1.00 1.00
1.00 3.00 5.00 1.00 3.00 5.00
L/H L/H
膨胀率-W/W0
8147 8155
y = 0.012x + 1.054 y = 0.0172x + 1.0492
1.16 R² = 0.797 R² = 0.9157
1.20
W/W0(@r≒100)
1.15
W/W0(@r≒100)
1.12
1.10
1.08
1.05
1.04
1.00 3.00 5.00 1.00
1.00 3.00 5.00
L/H
L/H
Material Factors Affecting Die Swell
• Molecular Weight and Molecular Weight Distribution of Rubber (Rubber Elasticity)
• Reinforcing Filler (Carbon Black, Silica) Type and Loading
• Filler Dispersion Quality (Dispersive and Distributive)
Size and Shape Change for Rectangular Extrudate
W1
Location 1 H1 Die Plate
W2
Location 2 H2 Extrudate
H2 x W2
Size Change =
H1 x W1
H2 / W2
Shape Change =
H1 / W1
Factors Affect Extruded Profile Size and Shape change
Draw-ratio Effect on Profile Dimension
High drawratio of extrusion line speed reduces shape change in height and width
Profile Shape and Size Change with Draw-ratio
Profile Dimension Change with Draw-ratio
How to Use Die Swell Lab Data for Die Plate Design?
Correlation with Die Swell in Non-circular Die
Definition of Hydraulic Radius
Example:
(Assume the shear rate 25.81

is in the same region)
实验室与现场押出实验相关性
H/H0 at Rw about 100 W/W0 at Rw about 100
1.40
2.00
8133 8133
8147 8147
1.50 8155 1.20 8155
8207
Factory
8207
Factory
1.00
1.00
0.50
0.00 0.80
0.00 0.50 1.00 1.50 2.00 0.80 0.90 1.00 1.10 1.20 1.30 1.40
Lab. Lab.
Factory lab.
H/H0 W/W0 Rw H/H0 W/W0 Rw
8133 1.83 1.19 126.59 1.45 1.02 117.53
8147 1.58 1.08 105.29 1.54 1.10 118.64
8155 1.73 1.12 101.50 1.67 1.09 95.00
8207 1.40 1.08 108.06 1.21 1.08 111.00
小结：实验室与现场在口金L/H=5时,押出的膨胀率趋势相似。其他的数据还在建立。
Recommended Future Plan for CSTC
• Establish Shear Viscosity/Die Swell Measurement Capability for Compound Quality

Assurance: Viscosity vs. Shear rate in Power-law region.
(Tentatively, using Small Lab Extruder with Slit Die)
• Establish Die Swell Measurement Capability for Die Plate Design Guideline:
Die Swell Ratio vs. L/H at Power-law shear rate region.
(Tentatively, using Small Lab Extruder with Slit Die)
• Establish Correlation between Lab Die Swell Ratio and Production Extrusion Die
Plate Die Swell Ratio as function of shear rate and L/H under Production Conditions
• Establish Die Plate Design Guideline using Die Swell Data from Lab
How to Use Die Swell Lab Data for Die Plate Design?
(Assuming Die Swell Data from Slit Die)
Extrusion Die Plate
(hA)D (hB)D
(hE)D
LD
A B C D E F G H I
Hydralic Radius: RA RB RC RD RE RF RG RH RI
HA= 2 RA
L/H = LD/2 RA
Estimate Extruded Profile Height (hA)P from Die Swell Ratio Lab Data at LD/2 RA for Region A
Estimate Extruded Profile Height (hB)P from Die Swell Ratio Lab Data at LD/2 RB for Region B
•
•
•
Estimate Extruded Profile Height (hE)P from Die Swell Ratio Lab Data at LD/2 RE for Region E
ME3N Measurements
 Belt 1 for the cut-sections are investigated:
ME3N Measurements
 Belt 2 for the cut-sections are investigated:
ME3N Measurements
 Steel belt spacing increased for ME3N at grooves:
ME3N Measurements
 Steel belt spacing increased for ME3N at grooves:
Bridgestone Potenza RE92A Measurements
 MTC investigated a cut-section of Bridgestone Potenza RE92A with the
size of P225/50R17 from January 2008.
 Bridgestone Potenza RE92A P225/50R17 belt angles measured:
 Bridgestone Potenza RE92A P225/50R17 belt wire spacing is measured:
 Bridgestone Potenza RE92A P225/50R17 belt wire spacing is measured:
Belt 2 Spacing
2.5
1.5
Belt Spacing
[mm]
Belt 2
1
0.5
0
-100 -80 -60 -40 -20 0 20 40 60 80 100
x [mm]
Profile Dimension Control through Process Control
Dimension Change via Screw Speed (Single Extruder)
Size/Shape Change via Screw Speed (Single Extruder)
Dimension Change via Takeaway Speed (Single Extruder)
Qtotal = Qi + Qj + Qq
Qi = ki Nj =Ui Ai
Ai = ki Nj Ui
xi = mi Ai = mi ki ( Nj Ui ) = Ki ( Nj Ui)
For Single Extruder :
xi = Ki ( Nj Ui) for a specific dimension
For multiple Extruders :
xi ni = Ki ( Nj Ui) for a specific dimension
Dimension Change via Screw and Takeaway (Multiple Extruders)
For multiple Extruders :
xi ni = Ki ( Nj Ui) for a specific dimension
Dimension Change via Screw and Takeaway (Multiple Extruders)
Example: Increasing N2 from Extruder # 2
Beginning Ending
Increasing N2 from Extruder # 2
Summary
• For the same extruder, through-put is decided by Screw speed, Head pressure,
and Viscosity.
• Screw Speed and Head Pressure affect Extrudate temperature. Viscosity is

affected by Temperature and Shear Rate.
• Compound Viscosity has Important Impact to Extrusion operation such as

Though-put and Head Pressure.
• Compound Die Swell information is Important to Die Plate design. Die Swell is
a function of Shear Rate and the Ratio of flow length (L) and critical exit Dimensions
such as L/D, L/H, and L/W.
• Profile dimension control through Process control is also important.

Both Screw speed and Draw ratio are important factors to have impact on
profile dimensions.

Extrusion Die Design and Process Control for Dimensional Stability

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Extrusion Die Design and Process Control for Dimensional Stability

Transféré par

Droits d'auteur :

Formats disponibles

Extrusion Process and Die Design Consideration

for Extrudate Dimension Control

• Rubber Compound Extrusion Operation

• Shear Viscosity and Die Swell of Rubber Compound

• Factors Affect Extruded Profile Size and Shape Change

• Profile Dimension Control through Process Control

Q = Qd (Drag flow) + Qp (Pressure flow)

• Through-put increases with

• Through-put decreases with

• Stock temperature increases

Shear Rate Range for Rubber Processing

Viscosity : characterizing resistance to flow of liquids

• Rabinowitsch Correction for Non-Newtonian Fluid

• Bagley’s Correction for End Effect

Wall Shear Rate

Wall Shear Rate

Normal stress difference (related Die Swell)

Capillary Die Swell

Die Swell from Three Different Capillary Dies.

Die plate region

Die Swell in a Slit Die

口金 ID 口金高度 口金深度 Lo/Ho

020 0.7 (mm) 4.5 (mm) 6.42

030 0.9 4.5 5

040 1.35 5 3.7

073 2 2.75 1.38

• Molecular Weight and Molecular Weight Distribution of Rubber (Rubber Elasticity)

• Reinforcing Filler (Carbon Black, Silica) Type and Loading

• Filler Dispersion Quality (Dispersive and Distributive)

Definition of Hydraulic Radius

(Assume the shear rate 25.81

• Establish Shear Viscosity/Die Swell Measurement Capability for Compound Quality

For Single Extruder :

xi = Ki ( Nj Ui) for a specific dimension

For multiple Extruders :

xi ni = Ki ( Nj Ui) for a specific dimension

For multiple Extruders :

xi ni = Ki ( Nj Ui) for a specific dimension

Increasing N2 from Extruder # 2

• Screw Speed and Head Pressure affect Extrudate temperature. Viscosity is

• Compound Viscosity has Important Impact to Extrusion operation such as

• Profile dimension control through Process control is also important.

Vous aimerez peut-être aussi

口金 ID 口金高度口金深度 Lo/Ho