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Troubleshooting extrusion problems is one of the most challenging tasks in extrusion operations, requiring a good understanding of the extrusion process and the material properties, good instrumentation, good analysis tools, and a systematic and logical approach. This book addresses all issues crucial in extrusion troubleshooting. Additionally, it includes industrial case studies, richly illustrated with photographs and photomicrographs, used to provide exemplary approaches to efficient problem analysis and problem solving. The interconnectivity between the different relevant knowledge areas such as materials engineering, processing technology, and product development is emphasized. This revised third edition comprises a very significant update, with a great deal of new content, especially focusing on additional case studies as well as new sections on collection and interpretation of extrusion process data, rotational rheometry, the smartphone, how screw design can affect extruder performance, melt temperature variation, recent research on automatic optimization of extruder barrel temperatures, process signal analysis using Fast Fourier Transform, among other topics.
The second edition of Extrusion is designed to aid operators, engineers, and managers in extrusion processing in quickly answering practical day-to-day questions. The first part of the book provides the fundamental principles, for operators and engineers, of polymeric materials extrusion processing in single and twin screw extruders. The next section covers advanced topics including troubleshooting, auxiliary equipment, and coextrusion for operators, engineers, and managers. The final part provides applications case studies in key areas for engineers such as compounding, blown film, extrusion blow molding, coating, foam, and reprocessing. This practical guide to extrusion brings together both equipment and materials processing aspects. It covers basic and advanced topics, for reference and training, in thermoplastics processing in the extruder. Detailed reference data are provided on such important operating conditions as temperatures, start-up procedures, shear rates, pressure drops, and safety. - A practical guide to the selection, design and optimization of extrusion processes and equipment - Designed to improve production efficiency and product quality - Focuses on practical fault analysis and troubleshooting techniques
This comprehensive book on troubleshooting PVC extrusion contains information on a wide range of topics with the emphasis on compounding, additives and also giving the knowledge about the combination of woody materials with PVC to wood polymer composites (WPC) is gaining more and more attraction in USA and Europe and a wide range of commercial products are already available on the market, but the troubleshooting areas are not covered well.
This handbook provides a framework for understanding how to characterize plastic manufacturing processes for use in troubleshooting problems. The 21 chapters are authored by well-known and experienced engineers who have specialized knowledge about the processes covered in this practical guide. From the Preface: “In every chapter, the process is described and the most common problems are discussed along with the root causes and potential technical solutions. Numerous case studies are provided that illustrate the troubleshooting process. Mark A. Spalding, The Dow Chemical Company
The author presents single-screw extrusion technology together with the relevant polymer fundamentals, with an emphasis on screw design. The presentation begins on a physical level providing an in-depth tutorial for conceptual understanding, followed by an analytical level with mathematical models. Practical applications of the mathematical models are illustrated by examples. A brief description of twin-screw extrusion technology is also presented. The second edition includes new chapters on die design, elastic effects in melt flow, and a new type of single-screw extruder with channeled barrel as well as improvements and corrections in the first edition. Content: " Physical Description of Single-Screw Extrusion " Fundamentals of Polymers and Melt Rheology " Theory of Single-Screw Extrusion and Scale-Up " Screw Design and High Performance Screws " Gear Pumps, Static Mixers, and Dynamic Mixers " Physical Description of Twin-Screw Extruders " Die Design " Elastic Effects in Melt Flow " Special Single-Screw Extruder with Channeled Barrel
The Basics of Troubleshooting in Plastics Processing is a condensed practical guide that gives the reader a broad introduction to properties of thermoplastics plastics, additives, the major processes (extrusion, injection molding, rotational molding, blow molding, and thermoforming), as well as troubleshooting. The main goal is to provide the plastics processor with an improved understanding of the basics by explaining the science behind the technology. Machine details are minimized as the emphasis is on processing problems and the defects in an effort to focus on basic root causes to problems and how to solve them. The book’s framework is troubleshooting in plastics processing because of the importance it has to the eventual production of high quality end products. Each chapter contains both practical and detailed technical information. This basic guide provides state-of-the-art information on: Processing problems and defects during manufacturing Plastics materials, their properties and characterization The plastics processing techniques Plastics additives Troubleshooting of the 5 main plastics processes References for further reading
Why is it important to get to equilibrium and how long does it take? Are there problems running polypropylene profiles on a single screw extruder? Does the job involve compounding color concentrates on a corotating twin screw extruder? This unique reference work is designed to aid operators, engineers, and managers in quickly answering such practical day-to-day questions in extrusion processing. This comprehensive volume is divided into 7 Parts. It contains detailed reference data on such important operating conditions as temperatures, start-up procedures, shear rates, pressure drops, and safety. This reference is a practical guide to extrusion bringing together both the equipment and materials processing aspects. It provides basic and advanced topics about the thermoplastics processing in the extruder, for reference and training. Parts 1 û 3, emphasize the fundamentals, for operators and engineers, of polymeric materials extrusion processing in single and twin screw extruders. Parts 4 û 7 treat advanced topics including troubleshooting, auxiliary equipment, and coextrusion for operators, engineers, and managers. Extensive applications in Part 7 cover such contemporary areas as compounding, blown film, extrusion blow molding, coating, foam, and reprocessing. Each chapter includes review topics.
"The book provides a practical understanding of basic information on extrusion in a way useful to readers without an engineering degree as well as to those new to the field. It is primarily written for extruder operators, supervisors, technical service personnel, and process engineers. Designed for on-the-job use, it guides the reader step by step through material issues, machinery, processing, and troubleshooting. This revised and extended third edition now also covers interpretation of extrusion process data, analysis of shrink void formation, dimensional variation by melt temperature fluctuations, efficient extrusion, grooved barrel extruder technology, and more. Contents: Extrusion Machinery Instrumentation and Control Complete Extrusion Lines Plastics and Their Properties Important in Extrusion How an Extruder Works How to Run an Extruder How to Troubleshoot Extrusion Problems New Developments in Extrusion and Methods to Increase Efficiency"--
Initially published "to bridge the gap between theory and practice in extrusion," this 5th edition of Polymer Extrusion continues to serve the practicing polymer engineer and chemist, providing the theoretical and the practical tools for successful extrusion operations. In its revised and expanded form, it also incorporates the many new developments in extrusion theory and machinery over the last years. Contents · Different Types of Extruders · Extruder Hardware · Instrumentation and Control · Fundamental Principles · Important Polymer Properties · Functional Process Analysis · Extruder Screw Design · Die Design · Twin Screw Extruders · Troubleshooting Extruders · Modeling and Simulation of the Extrusion Process
Prior extrusion books are based on barrel rotation physics—this is the first book that focuses on the actual physics of the process—screw rotation physics. In the first nine chapters, theories and math models are developed. Then, these models are used to solve actual commercial problems in the remainder of the book. Realistic case studies are presented that are unique in that they describe the problem as viewed by a typical plant engineer and provide the actual dimensions of the screws. Overall, there is not a book on the market with this level of detail and disclosure. The new knowledge in this book will be highly useful for production engineers, technical service engineers working with customers, consultants specializing in troubleshooting and process design, and process researchers and designers that are responsible for processes that running at maximum rates and maximum profitability. The second edition is brought up to date with a significant amount of new content, as well as minor improvements and correction of errors throughout.The new content includes transfer lines, percolation theory, fillers, and several more case studies.