Analyzing and troubleshooting single-screw extruders

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 re...

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Bibliographic Details
Main Authors	Campbell, G. A. Professor (Author), Spalding, Mark A. (Author)
Format	Electronic eBook
Language	English
Published	Munich, Germany ; Cincinnati, Ohio : Hanser Publishers, [2021]
Edition	2nd edition.
Subjects	Plastics > Extrusion. Screw pumps. elektronické knihy electronic books
Online Access	Full text
ISBN	9781569907856 1569907854 9781569907849
Physical Description	1 online resource : illustrations

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Table of Contents:

Intro
Contents
Preface
Acknowledgements
1 Single-Screw Extrusion: Introduction and Troubleshooting
1.1 Organization of this Book
1.2 Troubleshooting Extrusion Processes
1.2.1 The Injection Molding Problem at Saturn
1.3 Introduction to Screw Geometry
1.3.1 Screw Geometric Quantitative Characteristics
1.4 Simple Flow Equations for the Metering Section
1.5 Example Calculations
1.5.1 Example 1: Calculation of Rotational and Pressure Flow Components
1.5.2 Example 2: Flow Calculations for a Properly Operating Extruder
1.5.3 Example 3: Flow Calculations for an Improperly Operating Extruder
1.5.4 Metering Channel Calculation Summary
Nomenclature
References
2 Polymer Materials
2.1 Introduction and History
2.1.1 History of Natural Polymers
2.1.2 The History of Synthetic Polymers
2.2 Characteristics of Synthetic Polymers
2.3 Structure Effects on Properties
2.3.1 Stereochemistry
2.3.2 Melting and Glass Transition Temperatures
2.3.3 Crystallinity
2.4 Polymer Production and Reaction Engineering
2.4.1 Condensation Reactions
2.4.2 Addition Reactions
2.5 Polymer Degradation
2.5.1 Ceiling Temperature
2.5.2 Degradation of Vinyl Polymers
2.5.3 Degradation of Condensation Polymers
References
3 Introduction to Polymer Rheology for Extrusion
3.1 Introduction to the Deformation of Materials
3.2 Introduction to Basic Concepts of Molecular Size
3.2.1 Size Distribution Example
3.2.2 Molecular Weight Distributions for Polymers
3.3 Basic Rheology Concepts
3.4 Polymer Solution Viscosity and Polymer Molecular Weight
3.4.1 Sample Calculation of Solution Viscosity
3.5 Introduction to Viscoelasticity
3.6 Measurement of Polymer Viscosity
3.6.1 Capillary Rheometers
3.6.2 Cone and Plate Rheometers
3.6.3 Melt Index and Melt Flow Rate.
3.7 Viscosity of Polymers as Functions of Molecular Character, Temperature, and Pressure
3.8 Historical Models for Non-Newtonian Flow
3.9 Power Law and Viscosity Shear Rate Dependence
3.9.1 Shear Stress from Newtonian to Infinite Shear
3.9.2 Viscosity as a Function of Shear Rate
3.9.3 The Power Law and Process Dissipation
3.9.4 Viscosity, Shear Rate, and Dissipation
3.9.5 Percolation in Structured Systems
3.9.6 Tube Flow Data and Data Analysis
3.9.7 Dispersion Based Power Law Constant n
3.9.8 Rheological Implictions for Extrusion and Molding Processes
Nomenclature
References
4 Resin Physical Properties Related to Processing
4.1 Bulk Density and Compaction
4.1.1 Measurement of Bulk Density
4.1.2 Measuring the Compaction Characteristics of a Resin
4.2 Lateral Stress Ratio
4.2.1 Measuring the Lateral Stress Ratio
4.3 Stress at a Sliding Interface
4.3.1 The Screw Simulator and the Measurement of the Stress at the Interface
4.4 Melting Flux
4.5 Heat Capacity
4.6 Thermal Conductivity and Heat Transfer
4.7 Melt Density
Nomenclature
References
5 Solids Conveying
5.1 Description of the Solids Conveying Process
5.2 Literature Review of Smooth-Bore Solids Conveying Models
5.2.1 Darnell and Mol Model
5.2.2 Tadmor and Klein Model
5.2.3 Clarkson University Models
5.2.4 Hyun and Spalding Model
5.2.5 Moysey and Thompson Model
5.3 Modern Experimental Solids Conveying Devices
5.3.1 Solids Conveying Devices at Clarkson University
5.3.2 The Solids Conveying Device at Dow
5.4 Comparison of the Modified Campbell-Dontula Model with Experimental Data
5.4.1 Solids Conveying Example Calculation
5.5 Grooved Bore Solids Conveying
5.5.1 Grooved Barrel Solids Conveying Models
5.6 Solids Conveying Notes
Nomenclature
References
6 The Melting Process.
6.1 Compression Ratio and Compression Rate
6.2 The Melting Process
6.2.1 The Melting Process as a Function of Screw Geometry
6.2.2 Review of the Classical Literature
6.2.3 Reevaluation of the Tadmor and Klein Melting Data
6.3 Theory Development for Melting Using Screw Rotation Physics
6.3.1 Melting Model for a Conventional Transition Section Using Screw Rotation Physics
6.3.2 Melting Models for Barrier Screw Sections
6.4 Effect of Pressure on Melting Rate
6.5 One-Dimensional Melting
6.5.1 One-Dimensional Melting Model
6.6 Solid Bed Breakup
6.7 Melting Section Characteristics
Nomenclature
References
7 Fluid Flow in Metering Channels
7.1 Introduction to the Reference Frame
7.2 Laboratory Observations
7.3 Literature Survey
7.4 Development of Linearized Flow Analysis
7.4.1 Example Flow Calculation
7.5 Numerical Flow Evaluation
7.5.1 Simulation of a 500 mm Diameter Melt-Fed Extruder
7.5.2 Extrusion Variables and Errors
7.5.3 Corrections to Rotational Flow
7.5.4 Simulation of the 500 mm Diameter Extruder Using Fc
7.6 Frame Dependent Variables
7.6.1 Example Calculation of Energy Dissipation
7.7 Viscous Energy Dissipation and Temperature of the Resin in the Channel
7.7.1 Energy Dissipation and Channel Temperature for Screw Rotation
7.7.2 Energy Dissipation and Channel Temperature for Barrel Rotation
7.7.3 Temperature Increase Calculation Example for a Screw Pump
7.7.4 Heat Transfer Coefficients
7.7.5 Temperature Calculation Using a Control Volume Technique
7.7.6 Numerical Comparison of Temperatures for Screw and Barrel Rotations
7.8 Metering Section Characteristics
Nomenclature
References
8 Mixing Processes for Single-Screw Extruders
8.1 Common Mixing Operations for Single-Screw Extruders
8.1.1 Common Mixing Applications.
8.2 Dispersive and Distributive Mixing Processes
8.3 Fundamentals of Mixing
8.3.1 Measures of Mixing
8.3.2 Experimental Demonstration of Mixing
8.4 The Melting Process as the Primary Mechanism for Mixing
8.4.1 Experimental Analysis of the Melting and Mixing Capacity of a Screw
8.4.2 Mixing and Barrier-Flighted Melting Sections
8.5 Secondary Mixing Processes and Devices
8.5.1 Maddock-Style Mixers
8.5.2 Blister Ring Mixers
8.5.3 Spiral Dam Mixers
8.5.4 Pin-Type Mixers
8.5.5 Knob Mixers
8.5.6 Gear Mixers
8.5.7 Dynamic Mixers
8.5.8 Static Mixers
8.6 Mixing Using Natural Resins and Masterbatches
8.7 Mixing and Melting Performance as a Function of Flight Clearance
8.8 High Pressures During Melting and Agglomerates
8.9 Effect of Discharge Pressure on Mixing
8.10 Shear Refinement
8.11 Direct Compounding Using Single-Screw Extruders
Nomenclature
References
9 Scaling of Single-Screw Extrusion Processes
9.1 Scaling Rules
9.2 Engineering Design Method for Plasticating Screws
9.2.1 Process Analysis and Simulations
9.3 Scale-Up from a 40 mm Diameter Extruder to an 80 mm Diameter Machine for a PE Resin
9.4 Rate Increase for an 88.9 mm Diameter Extruder Running a HIPS Resin
Nomenclature
References
10 Introduction to Troubleshooting the Extrusion Process
10.1 The Troubleshooting Process
10.2 Hypothesis Setting and Problem Solving
10.2.1 Case Study for the Design of a New Resin
10.2.2 Case Study for a Surface Blemish
10.2.3 Case Study for a Profile Extrusion Process
10.3 Equipment and Tools Needed for Troubleshooting
10.3.1 Maddock Solidification Experiment
10.4 Common Mechanical Problems
10.4.1 Flight Clearance and Hard Facing
10.4.2 Barrel and Screw Alignment
10.4.3 Extruder Barrel Supports
10.4.4 First-Time Installation of a Screw.
10.4.5 Screw Breaks
10.4.6 Protection from High-Pressure Events
10.4.7 Gearbox Lubricating Oil
10.4.8 Particle Seals and Viscoseals
10.4.9 Screw Cleaning
10.5 Common Electrical and Sensor Problems
10.5.1 Thermocouples
10.5.2 Pressure Sensors
10.5.3 Electronic Filters and Noise
10.6 Motors and Drive Systems
10.6.1 Motor Efficiencies and Power Factors
10.7 Typical Screw Channel Dimensions
10.8 Common Calculations
10.8.1 Energy Dissipated by the Screw
10.8.2 Screw Geometry Indices
10.9 Barrel Temperature Optimization
10.10 Screw Temperature Profile
10.11 The Screw Manufacturing and Refurbishing Process
10.12 Injection-Molding Plasticators
10.12.1 Calculations for Injection-Molding Plasticators
10.13 New Equipment Installations
10.13.1 Case Study: A Large Diameter Extruder Purchase
10.13.2 Case Study: Extruder and Line Purchase for a New Product
10.13.3 A High-Density Foamed Sheet Product
10.13.4 Summary for New Equipment Installations
Nomenclature
References
11 Contamination in the Finished Product
11.1 Foreign Contaminants in the Extrudate
11.1.1 Melt Filtration
11.1.2 Metal Fragments in the Extrudate
11.1.3 Gas Bubbles in a New Sheet Line
11.2 Gels in Polyolefin Resins
11.2.1 Protocols for Gel Analysis
11.3 Resin Decomposition in Stagnant Regions of a Process
11.3.1 Transfer Lines
11.4 Improper Shutdown of Processing Equipment
11.5 Equipment Purging
11.6 Oxygen Exclusion at the Hopper
11.7 Flight Radii Size
11.8 Drying the Resin
11.9 Color Masterbatches
11.10 Case Studies for Extrusion Processes with Contamination in the Product
11.10.1 Intermittent Crosslinked Gels in a Film Product
11.10.2 Small Gels in an LLDPE Film Product
11.10.3 Degassing Holes in Blow-Molded Bottles.

Analyzing and troubleshooting single-screw extruders

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