Abstract: This study optimized the performance of plastic extrusion process of drip irrigation pipes using fuzzy goal programming. Two main responses were of main interest; roll thickness and hardness. Four main process factors were studied. The L18 array was then used for experimental design. The individual-moving range control charts were used to assess the stability of the process, while the process capability index was used to assess process performance. Confirmation experiments were conducted at the obtained combination of optimal factor setting by fuzzy goal programming. The results revealed that process capability was improved significantly from -1.129 to 0.8148 for roll thickness and from 0.0965 to 0.714 and hardness. Such improvement results in considerable savings in production and quality costs.
Abstract: Plastic extrusion has been an important process of plastic production since 19th century. Meanwhile, in plastic extrusion process, wide variation in temperature along the extrudate usually leads to scraps formation on the side of finished products. To avoid this situation, there is a need to deeply understand temperature distribution along the extrudate in plastic extrusion process. This work developed an analytical model that predicts the temperature distribution over the billet (the polymers melt) along the extrudate during extrusion process with the limitation that the polymer in question does not cover biopolymer such as DNA. The model was solved and simulated. Results for two different plastic materials (polyvinylchloride and polycarbonate) using self-developed MATLAB code and a commercially developed software (ANSYS) were generated and ultimately compared. It was observed that there is a thermodynamic heat transfer from the entry level of the billet into the die down to the end of it. The graph plots indicate a natural exponential decay of temperature with time and along the die length, with the temperature being 413 K and 474 K for polyvinylchloride and polycarbonate respectively at the entry level and 299.3 K and 328.8 K at the exit when the temperature of the surrounding was 298 K. The extrusion model was validated by comparison of MATLAB code simulation with a commercially available ANSYS simulation and the results favourably agree. This work concludes that the developed mathematical model and the self-generated MATLAB code are reliable tools in predicting temperature distribution along the extrudate in plastic extrusion process.
Abstract: The composite flour blend consisting of corn, pearl
millet, black gram and wheat bran in the ratio of 80:5:10:5 was taken
to prepare the extruded product and their effect on physical properties
of extrudate was studied. The extrusion process was conducted in
laboratory by using twin screw extruder. The physical characteristics
evaluated include lateral expansion, bulk density, water absorption
index, water solubility index, and rehydration ratio and moisture
retention. The Central Composite Rotatable Design (CCRD) was
used to decide the level of processing variables i.e. feed moisture
content (%), screw speed (rpm), and barrel temperature (oC) for the
experiment. The data obtained after extrusion process were analyzed
by using response surface methodology. A second order polynomial
model for the dependent variables was established to fit the
experimental data. The numerical optimization studies resulted in
127°C of barrel temperature, 246 rpm of screw speed, and 14.5% of
feed moisture as optimum variables to produce acceptable extruded
product. The responses predicted by the software for the optimum
process condition resulted in lateral expansion 126%, bulk density
0.28 g/cm3, water absorption index 4.10 g/g, water solubility index
39.90%, rehydration ratio 544% and moisture retention 11.90% with
75% desirability.
Abstract: The tensile properties of Mg-3%Al nanocrystalline
alloys were investigated at different test environment. Bulk
nanocrystalline samples of these alloy was successfully prepared by
mechanical alloying (MA) followed by cold compaction, sintering,
and hot extrusion process. The crystal size of the consolidated milled
sample was calculated by X-Ray line profile analysis. The
deformation mechanism and microstructural characteristic at
different test condition was discussed extensively. At room
temperature, relatively lower value of activation volume (AV) and
higher value of strain rate sensitivity (SRS) suggests that new rate
controlling mechanism accommodating plastic flow in the present
nanocrystalline sample. The deformation behavior and the
microstructural character of the present samples were discussed in
details.
Abstract: The simulation of extrusion process is studied widely
in order to both increase products and improve quality, with broad
application in wire coating. The annular tube-tooling extrusion was
set up by a model that is termed as Navier-Stokes equation in
addition to a rheological model of differential form based on singlemode
exponential Phan-Thien/Tanner constitutive equation in a twodimensional
cylindrical coordinate system for predicting the
contraction point of the polymer melt beyond the die. Numerical
solutions are sought through semi-implicit Taylor-Galerkin pressurecorrection
finite element scheme. The investigation was focused on
incompressible creeping flow with long relaxation time in terms of
Weissenberg numbers up to 200. The isothermal case was considered
with surface tension effect on free surface in extrudate flow and no
slip at die wall. The Stream Line Upwind Petrov-Galerkin has been
proposed to stabilize solution. The structure of mesh after die exit
was adjusted following prediction of both top and bottom free
surfaces so as to keep the location of contraction point around one
unit length which is close to experimental results. The simulation of
extrusion process is studied widely in order to both increase products
and improve quality, with broad application in wire coating. The
annular tube-tooling extrusion was set up by a model that is termed
as Navier-Stokes equation in addition to a rheological model of
differential form based on single-mode exponential Phan-
Thien/Tanner constitutive equation in a two-dimensional cylindrical
coordinate system for predicting the contraction point of the polymer
melt beyond the die. Numerical solutions are sought through semiimplicit
Taylor-Galerkin pressure-correction finite element scheme.
The investigation was focused on incompressible creeping flow with
long relaxation time in terms of Weissenberg numbers up to 200. The
isothermal case was considered with surface tension effect on free
surface in extrudate flow and no slip at die wall. The Stream Line
Upwind Petrov-Galerkin has been proposed to stabilize solution. The
structure of mesh after die exit was adjusted following prediction of
both top and bottom free surfaces so as to keep the location of
contraction point around one unit length which is close to
experimental results.
Abstract: This paper deals with the evaluation of flow properties
of polymeric matrix with natural animal fillers. Technical university
of Liberec cooperates on the long-term development of “green
materials“ that should replace conventionally used materials
(especially in automotive industry). Natural fibres (of animal and
plant origin) from all over the world are collected and adapted
(drying, cutting etc.) for extrusion processing. Inside the extruder
these natural additives are blended with polymeric (synthetic and
biodegradable - PLA) matrix and created compound is subsequently
cut for pellets in the wet way. These green materials with unique
recipes are then studied and their mechanical, physical and
processing properties are determined. The main goal of this research
is to develop new ecological materials very similar to unfilled
polymers. In this article the rheological behaviour of chosen natural
animal fibres is introduced considering their shape and surface that
were observed with use of SEM microscopy.
Abstract: In the process of polyethylene extrusion polymer
material similar to powder or granule is under compression, melting
and transmission operation and on base of special form, extrudate has
been produced. Twin-screw extruders are applicable in industries
because of their high capacity. The powder mixing with chemical
additives and melting with thermal and mechanical energy in three
zones (feed, compression and metering zone) and because of gear
pump and screw's pressure, converting to final product in latest plate.
Extruders with twin-screw and short distance between screws are
better than other types because of their high capacity and good
thermal and mechanical stress.
In this paper, process of polyethylene extrusion and various tapes
of extruders are studied. It is necessary to have an exact control on
process to producing high quality products with safe operation and
optimum energy consumption.
The granule size is depending on granulator motor speed. Results
show at constant feed rate a decrease in granule size was found whit
Increase in motor speed. Relationships between HDPE feed rate and
speed of granulator motor, main motor and gear pump are calculated
following as:
x = HDPE feed flow rate, yM = Main motor speed
yM = (-3.6076e-3) x^4+ (0.24597) x^3+ (-5.49003) x^2+ (64.22092)
x+61.66786 (1)
x = HDPE feed flow rate, yG = Gear pump speed
yG = (-2.4996e-3) x^4+ (0.18018) x^3+ (-4.22794) x^2+ (48.45536)
x+18.78880 (2)
x = HDPE feed flow rate, y = Granulator motor speed
10th Degree Polynomial Fit: y = a+bx+cx^2+dx^3... (3)
a = 1.2751, b = 282.4655, c = -165.2098,
d = 48.3106, e = -8.18715, f = 0.84997
g = -0.056094, h = 0.002358, i = -6.11816e-5
j = 8.919726e-7, k = -5.59050e-9
Abstract: The plastic flow of metal in the extrusion process is
an important factor in controlling the mechanical properties of the
extruded products. It is, however, difficult to predict the metal flow
in three dimensional extrusions of sections due to the involvement of
re-entrant corners. The present study is to find an upper bound
solution for the extrusion of triangular sectioned through taper dies
from round sectioned billet. A discontinuous kinematically
admissible velocity field (KAVF) is proposed. From the proposed
KAVF, the upper bound solution on non-dimensional extrusion
pressure is determined with respect to the chosen process parameters.
The theoretical results are compared with experimental results to
check the validity of the proposed velocity field. An extrusion setup
is designed and fabricated for the said purpose, and all extrusions are
carried out using circular billets. Experiments are carried out with
commercially available lead at room temperature.
Abstract: The objective of this paper is to estimate realistic
principal extrusion process parameters by means of artificial neural
network. Conventionally, finite element analysis is used to derive
process parameters. However, the finite element analysis of the
extrusion model does not consider the manufacturing process
constraints in its modeling. Therefore, the process parameters
obtained through such an analysis remains highly theoretical.
Alternatively, process development in industrial extrusion is to a
great extent based on trial and error and often involves full-size
experiments, which are both expensive and time-consuming. The
artificial neural network-based estimation of the extrusion process
parameters prior to plant execution helps to make the actual extrusion
operation more efficient because more realistic parameters may be
obtained. And so, it bridges the gap between simulation and real
manufacturing execution system. In this work, a suitable neural
network is designed which is trained using an appropriate learning
algorithm. The network so trained is used to predict the
manufacturing process parameters.