James L. White / Helmut Potente (Editors) Screw Extrusion. Science and Technology

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1 James L. White / Helmut Potente (Editors) Screw Extrusion Science and Technology With Contributions from U. Berghaus, E. Bürkle, H. Potente, H. Recker, K. Schäfer, V. Schöppner, J.L. White, G. Wiegand, M. Wtlrtele HANSER Hanser Publishers, Munich Hanser Gardner Publications, Inc., Cincinnati

2 Contents 1 Introduktion Overview Historical Development Early Period to to to Present Earlier Books on Screw Extrusion 7 References 9 2 Fundamentals Introduction Pumping Mechanisms General Positive Displacement Pumps Ram Extruders Rotary Positive Displacement Pumps Drag Flow Pumps Normal Stress Pump Specifications of Screws Single Screw Pumps Principles Simple Screw Design Features Counter-Rotating Twin Screw Machine Tangential Intermeshed Co-Rotating Twin Screw Machine Multiple-Screw Extrusion 35 References 37 3 Screw Extrusion Technology Rubber Extrusion Introduction Extruder Technology Hot-Feed and Cold-Feed Extruders Special Screw Designs for Cold-Feed Extruders Plastication and Homogenization Vacuum Extruders Overall Screw Extruder Design Basic Experimental Studies General Plasticating and Homogenization Screws Pin Barrel Extruders Vacuum Extruders 55

3 x Contents Flow Simulations Rheological Properties of Rubber Compounds Simple Screws Screw Sections with Slices Pin Barrel Extruders Multilayer Extrusion Lines Continuous Vulcanization Lines 60 References Extrusion of Thermoplastics Trends in the Development of Single-Screw Extruders High-Speed Extruders with Melt Pumps Grooved Feed Extruders with 30D or 33D Screws Feed Section Design Screw Designs Increased Output Without Increase in Wear Homogenizing, In-Line Dispersion Barrier Screw Vented Extruders with 33D or 36D Screws Reduced Wear as a Result of Appropriate Material Selection Single Screw Extrusion Technologies Blown Film - A Classic Product with Good Properties Double-Bubble Process for Biaxially Oriented Blown Film Cast Films-Quality of the Highest Standard Extrusion Coating - Improved Quality for Composites Plastic Sheets and Thermoforming Sheets - In Highest Quality for a Host of Applications Plastic Pipes and Profiles - The Ideal Components for Civil Engineering and Technological Applications Synthetic Filaments - Monofilaments, Slit Film Tapes, and Strapping Tapes Monofilaments Slit Film Tapes Stapping Tapes Nonwoven Textiles - The Cost-Effective Alternative Outlook Design Conditions Processing Conditions 95 References Screw Design Introduction Evaluation and Specification Specification of the Input Variables Material Drive Temperature Control Downstream Equipment Quality Criteria of the Output Values Quality Criteria Within an Extruder Quantification of the Quality Criteria Subdivision into Operating Zones and Types of Construction 105

4 Contents xi Feeding Section Smooth Barrel Extruder Grooved-Barrel Extruder Melting Section Transition Zone BarrierZone Dispersive Melting Metering Zone Torpedoes Mixing Sections Special Geometries Combination of a Metering Zone with Shear or Mixing Elements Mixing Screws Dynamic Mixers Screw Construcion Types and Applications Plasticating Extruders Three-Section Screw Barrier Screw with Mixing Section Srew with Torpedo and Mixing Section Barrier Screw with Torpedo and Mixing Section for Grooved-Barrel Exruders Melt Extruders Vented Extruders Geometrical Design Design Strategy and Means Definition of an Appropriate Specific Throughput Optimization of the Single Function Zones Feeding Zone Melting Zone BarrierZone Pitches, Flight and Channel Width Zone Length, Feed, and Outlet Design Channel Depth Metering Zone Spiral Torpedo Section Faceted Mixing Torpedo Series Design Example: Extruder 090mm for 300 kg/h PET IV References Machine Design and Construction Extruder Size Components of a Single Screw Extruder Frame Extruder Drive Transmission and Clutch GearUnit Feeding Section Hopper 148

5 xii Contents Barrel Barrel Heating and Cooling Equipment Heating Extruder Cooling Screw Special Designs Spinning Extruder Adiabatic Extruder Vented Extruder Metering Extruder Tandem Extruders Vertical Extruder Extruder with Conical Feed Zone 160 References Measurement and Open-Loop and Closed-Loop Control Engineering Temperature Measurement and Closed-Loop Control Wall Temperature Melt Temperature Surface Temperature Closed-Loop Temperature Control Measurement and Closed-Loop Control of Pressure Melt Pressure Open-Loop Pressure Control Closed-Loop Pressure Control Closed-Loop Thickness Control with the Aid of Pressure and Temperature Measurements Measuring Specific Product Properties Dimensioning Surface Defect Recognition on Panels and Films Surface Inspection of Profiles Process Control on the Extruder Automation System Structures Centralized System Structure Networked Automation Systems Material Metering Closed-Loop Startup Control Process Control for Selected Extrusion Methods Tubular Film Plants Flat Film Plants Pipe and Profile Plants 176 References Technology of Single Screw Extrusion with Reciprocating Screws Screw Injection Molding Particularities Regarding the Transition from the Continuous to the Discontinuous Method of Operation Feed Zone Transition Section Melting Process During the Metering Period 188

6 Contents xiii Melting Process During Injection Screw Idle Time MeteringZone Mixing Zone Size Transposition Considering the Plasticizing Unit as a Whole Feed Performance Air Entrapment Swept Volume Feed Problems Melting Section Mixing Quality Homogeneity and Melt Temperature Influence of Processing Parameters on the Mixing Quality Residence Time 208 Nomenklature 209 References Buss Kneader Introduction Machine Technology Earlier Related Machines Origins of the Kneader Development of the Kneader Modern Kneader Basic Experimental Studies Flow Simulations General Flow Due to an Oscillating Screw Flux Patterns and Pumping Characteristics of Kneader Elements Theory of Composite Modular Machines Applications 225 References Single Screw Extruder Analysis and Design Melt Conveying Section Analysis Isothermal Analysis Melt Conveying Power Consumption Nonisothermal Analysis Melt Conveying Temperature Power Consumption Melts That Slip at the Wall One-Dimensional Treatment Two-Dimensional Treatment Melting Analysis Starting Point Melting 258

7 xiv Contents Requirements for the Mathematical Treatment Mathematical Tratment Regardless of the Leakage Flow Across the Screw Flight Velocity Profile in the Melt Film at the Barrel Wall Melting Velocity Temperature in the Melt Film at the Barrel Wall Heat Flows at the Boundary Layer Between the Melt film and the Soldid Bed Determination of the Exponent с and the Melt Film Thickness Solid Bed Profile and Melting Length Regardless of the Melting Film at the Screw Mathematical Treatment in Consideration of the Leakage Flow Across the Screw Fligth Mathematical Treatment of Melting During the Screw Downtime at Injection Molding Computation of the Melted Material Premelting Approaches for the Computation of the Melt Films at the Screw Pressure-Throughput Behavior and Power Comsumption in the Melting Zone Solid Conveying Smooth-Barrel Feed Zone Throughput Power Consumption Grooved Feed Section Throughput Power and Torque High-Speed Conveying Composite Extruder Models Integral Treatment Throughput Behavior of Smooth-Barrel Extruders with Melt- Dominated Conveying Throughput Behavior of Grooved Barrel Extruders Throughput Behavior of Ventintg Extruders Power Input Coupling the Models of the Function Zones Scale-Up Principle of Similarity General Formulation of the Scale-Up Rules Treatment by Zones Melt Conveying Zone Plasticating Zone Solid Conveying Smooth-Barrel Extruder Grooved-Barrel Extruder Summary Scale-Up Rules for Melt and Smooth-Barrel Plasticating Machines Scale-Up Rules for Grooved-Barrel Extruders 343 Nomenklature 346 References 349

8 Contents xv 6 Twin and Multiscrew Extrusion Introduction Intermeshing Co-Rotating Twin Screw Extrusion Technology Geometry Experimental Studies Early Studies to Flow Visualization Including Solid Conveying and Melting Residence Time Distributions Pumping Characteristics Heat Transfer Mixing Flow Modeling General Flow Pumping in Modules Screw Elements Kneading Disc Blocks Composite Modular Machine Behavior Melting and Composite Pumping Model Mixing Reactive Extrusion Applications Intermeshing Counter-Rotating Twin Screw Extrusion Technology Experimental Flow Visualization Residence Time Distributions Pumping Characteristics Melting Mixing Modeling General Leaking C-Chamber Models FAN Analysis of Flow Three-Dimensional Solutions Composite Pumping Model Screw Bending Applications Tangential Counter-Rotating Twin Screw Extruders Technology Experimental Flow Visualization Screw Pumping Characteristics Modeling General Analytical Flow Models Quantitative Flow Models Composite Modular Pumping Modeling Applications Continuous Mixers 419

9 xvi Contents Technology Experimental Modeling Applications 427 References 427 Subject Index 435 Name-Author Index 438

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