Polymer Extrusion

Author： Pierre G. Lafleur

Publisher： John Wiley & Sons Inc‎

Publication year： 2014

E-ISBN: 9781118827000

P-ISBN(Hardback): 9781848216501

Subject： O63 Polymer Chemistry (Polymer)

Language： ENG

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Description

Extrusion is by far the most important and the oldest processing and shaping method for thermoplastic polymers. This process concerns almost all synthetic polymers, as well as elastomers or food materials. Single-screw extrusion is mainly used nowadays to manufacture finished goods or semi-finished products. More than 90 million tons of thermoplastics are therefore processed every year.
Twin-screw extrusion may be divided into two systems: contra-rotating systems used within the context of PVC extrusion, for the manufacture of pipes or profiles; and co-rotating systems experiencing nowadays a very significant development, because of their significant adaptability and flexibility, which enables the manufacture of specific materials (polymer alloys, thermoplastic elastomers, filled polymers, nanocomposites). Extrusion is carried out by passing molten polymer through a tool called die that will give the product its final shape (films and sheets, rolled products, and electric cables). Thanks to the design of dies, we obtain at the output a product with controlled dimensions, uniform speeds and homogeneous temperatures. The book will discuss the same production types, but only in the case of coextrusion flows, i.e. multilayer stratified products. First of all, we will present in this book the physics of the mechanisms at stake, then propose more or less complex models in order to describe these mechanisms and then go forward in the interpretation of results and the control of condition flows.

Chapter

Chapter 1. Continuum Mechanics, Rheology and Heat Transfer Overview

1.1. Continuum mechanics

1.1.1. Strain

1.1.2. Strain rate

1.1.3. Stress

1.1.4. General equations in continuum mechanics

1.2. Rheology

1.2.1. Newtonian behavior

1.2.2. General viscous behavior

1.2.3. Effects on pressure and temperature

1.3. Heat transfer [CAR 59, BIR 60, AGA 14]

1.3.1. The thermal balance equation

1.3.2. Heat transfer during flow

1.3.3. Cooling temperature

1.4. Bibliography

Chapter 2. Calculation Methods

2.1. Introduction

2.2. 1D solutions

2.2.1. Isothermal calculation

2.2.2. Non-isothermal calculations

2.3. 2D solutions

2.3.1. Network method (or FAN method)

2.3.2. Finite element method

2.4. Bibliography

Chapter 3. Single-Screw Extrusion

3.1. Introduction

3.2. Geomentry and approximations

3.3. Solid conveying zone

3.3.1. Phenomenological description

3.3.2. Modeling

3.3.3. Synthesis

3.3.4. Determination of physical parameters

3.4. Melting zone

3.4.1. Phenomenological description

3.4.2. Modeling

3.5. Metering zone

3.5.1. Phenomenological description

3.5.2. Modeling

3.6. Overall model

3.7. Technological improvements

3.7.1. Grooved barrels

3.7.2. Barrier screws

3.7.3. Mixing heads

3.8. Conclusion

3.9. Bibliography

Chapter 4. Co-rotating Twin-Screw Extrusion

4.1. Twin-screw extrusion

4.1.1. The different types of extruders

4.1.2. Different flow types

4.2. General overview of co-rotating twin-screw extruders

4.2.1. Characteristic features of co-rotating twin-screw extruders

4.2.2. Geometry of the screws and barrel

4.2.3. Conventional approximations

4.3. Solid conveying zone

4.4. Melting zone

4.4.1. Experimental studies

4.4.2. Theoretical models

4.5. Flow in the molten state

4.5.1. Right- and left-handed screw element

4.5.2. Mixing elements

4.5.3. Heat transfer

4.5.4. Residence time distribution

4.6. An overall model of twin-screw extrusion

4.6.1. General description

4.6.2. Calculation algorithm

4.6.3. Residence time distribution

4.6.4. Example of results using the LUDOVIC© software

4.7. Compounding application and production of complex materials

4.7.1. Compounding and mixing

4.7.2. Reactive extrusion

4.7.3. Polymer blends

4.7.4. Production of clay-based nanocomposites

4.7.5. Optimization and scale-up

4.8. Conclusion

4.9. Bibliography

Chapter 5. Profile Extrusion

5.1. Profile extrusion

5.1.1 Different types of profile dies

5.1.2. Flow calculation inside profile dies

5.1.3. Evaluation of post-extrusion phenomena

5.1.4. Design of extrusion dies

5.2. Pipe extrusion

5.2.1. Introduction

5.2.2. Flow calculation

5.3. Calibrators

5.3.1. Friction calibrators

5.3.2. External compressed air calibrators

5.3.3. External vacuum calibrators

5.3.4. Internal calibrators

5.4. Conclusion

5.5. Bibliography

Chapter 6. Production of Films and Sheets

6.1. Introduction

6.2. Cast film extrusion

6.2.1. Processing

6.2.2. Designing the flat die

6.3. Film blowing

6.3.1. Process overview

6.3.2. Film blowing models

6.3.3. Multilayer films

6.4. Conclusion

6.5. Bibliography

Chapter 7. Wire Coating and Cable Insulation

7.1. General process

7.1.1. Production line

7.1.2. Wire coating dies

7.2. Commonly encountered problems

7.3. Analyses and solutions

7.3.1. Theoretical studies

7.3.2. Experimental studies

7.4. Conclusion

7.5. Bibliography

Index

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