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: Mustard leaves are rich in folates, vitamin A, K and
B-complex. Mustard greens are low in calories and fats and rich in
dietary fiber. They are rich in potassium, manganese, iron, copper,
calcium, magnesium and low in sodium. It is very rich in antioxidants
and Phytonutrients. For the optimization of process variables
(moisture content and mustard leave powder), the experiments were
conducted according to central composite Face Centered Composite
design of RSM. The mustard leaves powder was replaced with
composite flour (a combination of rice, chickpea and corn in the ratio
of 70:15:15). The extrudate was extruded in a twin screw extruder at
a barrel temperature of 120°C. The independent variables were
mustard leaves powder (2-10 %) and moisture content (12-20 %).
Responses analyzed were bulk density, water solubility index, water
absorption index, lateral expansion, antioxidant activity, total
phenolic content, and overall acceptability. The optimum conditions
obtained were 7.19 g mustard leaves powder in 100g premix having
16.8% moisture content (w.b).
Abstract: This research aims to develop an algorithm to
generate a schedule of multiple cranes that will maximize load
throughputs in anodizing operation. The algorithm proposed utilizes
an enumerative strategy to search for constant time between
successive loads and crane covering range over baths. The computer
program developed is able to generate a near-optimal crane schedule
within reasonable times, i.e. within 10 minutes. Its results are
compared with existing solutions from an aluminum extrusion
industry. The program can be used to generate crane schedules for
mixed products, thus allowing mixed-model line balancing to
improve overall cycle times.
Abstract: Encapsulated O-rings are specifically designed to address the problem of sealing the most hostile chemicals and extreme temperature applications. Ultrasonic vibration hot embossing and ultrasonic welding techniques provide a fast and reliable method to fabricate encapsulated O-ring. This paper performs the design and analysis method of the acoustic horns with double extrusion to process tube double side flange simultaneously. The paper deals with study through Finite Element Method (FEM) of ultrasonic stepped horn used to process a capsulated O-ring, the theoretical dimensions of horns, and their natural frequencies and amplitudes are obtained through the simulations of COMOSOL software. Furthermore, real horns were fabricated, tested and verified to proof the practical utility of these horns.
Abstract: PLA emerged as a promising polymer because of its
property as a compostable, biodegradable thermoplastic made from
renewable sources. PLA can be polymerized from monomers
(Lactide or Lactic acid) obtained by fermentation processes from
renewable sources such as corn starch or sugarcane. For PLA
synthesis, ring opening polymerization (ROP) of Lactide monomer is
one of the preferred methods. In the literature, the technique mainly
developed for ROP of PLA is based on metal/bimetallic catalyst (Sn,
Zn and Al) or other organic catalysts in suitable solvent. However,
the PLA synthesized using such catalysts may contain trace elements
of the catalyst which may cause toxicity. This work estimated the
usefulness and drawbacks of using different catalysts as well as effect
of alternative energies and future aspects for PLA production.
Abstract: In this study, composites were fabricated from oil
palm empty fruit bunch fiber and poly(lactic) acid by extrusion
followed by injection moulding. Surface of the fiber was pre-treated
by ultrasound in an alkali medium and treatment efficiency was
investigated by scanning electron microscopy (SEM) analysis and
Fourier transforms infrared spectrometer (FTIR). Effect of fiber
treatment on composite was characterized by tensile strength (TS),
tensile modulus (TM) and impact strength (IS). Furthermore,
biostrong impact modifier was incorporated into the treated fiber
composite to improve its impact properties. Mechanical testing
showed an improvement of up to 23.5% and 33.6% respectively for
TS and TM of treated fiber composite above untreated fiber
composite. On the other hand incorporation of impact modifier led to
enhancement of about 20% above the initial IS of the treated fiber
composite.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: In this study, tapioca starch, which acts as natural polymer, was added in the blend in order to produce biodegradable product. Low density polyethylene (LDPE) and tapioca starch blends were prepared by extrusion and the test sample by injection moulding process. Ethylene vinyl acetate (EVA) acts as compatibilizer while glycerol as processing aid was added in the blend. The blends were characterized by using melt flow index (MFI), fourier transform infrared (FTIR) and the effects of water absorption to the sample. As the starch content increased, MFI of the blend was decreased. Tensile testing were conducted shows the tensile strength and elongation at break decreased while the modulus increased as the starch increased. For the biodegradation, soil burial test was conducted and the loss in weight was studied as the starch content increased. Morphology studies were conducted in order to show the distribution between LDPE and starch.
Abstract: In this study tree types of multilayer gas barrier plastic packaging films were compared using life cycle assessment as a tool for resource efficient and environmentally low-impact materials selection. The first type of multilayer packaging film (PET-AlOx/LDPE) consists of polyethylene terephthalate with barrier layer AlOx (PET-AlOx) and low density polyethylene (LDPE). The second type of polymer film (PET/PE-EVOH-PE) is made of polyethylene terephthalate (PET) and co-extrusion film PE-EVOH-PE as barrier layer. And the third one type of multilayer packaging film (PET-PVOH/LDPE) is formed from polyethylene terephthalate with barrier layer PVOH (PET-PVOH) and low density polyethylene (LDPE).
All of analyzed packaging has significant impact to resource depletion, because of raw materials extraction and energy use and production of different kind of plastics. Nevertheless the impact generated during life cycle of functional unit of II type of packaging (PET/PE-EVOH-PE) was about 25% lower than impact generated by I type (PET-AlOx/LDPE) and III type (PET-PVOH/LDPE) of packaging.
Result revealed that the contribution of different gas barrier type to the overall environmental problem of packaging is not significant. The impact are mostly generated by using energy and materials during raw material extraction and production of different plastic materials as plastic polymers material as PE, LDPE and PET, but not gas barrier materials as AlOx, PVOH and EVOH.
The LCA results could be useful in different decision-making processes, for selecting resource efficient and environmentally low-impact materials.
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: Aluminum/Copper clad sheet has been fabricated using
asymmetric extrusion method, which caused severe shear deformation
between Al and Cu plate to easily bond to each other. Interfacial
microstructure and mechanical properties of Al/Cu clad were studied
by scanning electron microscope equipped with energy dispersive
X-ray detector, micro-hardness, and tension tests. The asymmetric
extrusion bonding was very effective to provide a good interface for
atoms diffusion during subsequent annealing. The strength of bonding
was higher with the increasing extrusion ratio.
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: In the present study, a numerical analysis is carried
out to investigate unsteady MHD (magneto-hydrodynamic) flow and
heat transfer of a non-Newtonian second grade viscoelastic fluid
over an oscillatory stretching sheet. The flow is induced due to an
infinite elastic sheet which is stretched oscillatory (back and forth) in
its own plane. Effect of viscous dissipation and joule heating are
taken into account. The non-linear differential equations governing
the problem are transformed into system of non-dimensional
differential equations using similarity transformations. A newly
developed meshfree numerical technique Element free Galerkin
method (EFGM) is employed to solve the coupled non linear
differential equations. The results illustrating the effect of various
parameters like viscoelastic parameter, Hartman number, relative
frequency amplitude of the oscillatory sheet to the stretching rate and
Eckert number on velocity and temperature field are reported in
terms of graphs and tables. The present model finds its application in
polymer extrusion, drawing of plastic films and wires, glass, fiber
and paper production etc.
Abstract: The influence of extrusion parameters on surface
quality and properties of AA6061+x% vol. SiC (x = 0; 2,5; 5; 7,5;10)
composites was discussed in this paper. The averages size of
AA6061 and SiC particles were 10.6 μm and 0.42 μm, respectively.
Two series of composites (I - compacts were preheated at extrusion
temperature through 0.5 h and cooled by water directly after process;
II - compacts were preheated through 3 hours and were not cooled)
were consolidated via powder metallurgy processing and extruded by
KoBo method. High values of density for both series of composites
were achieved. Better surface quality was observed for II series of
composites. Moreover, for these composites lower (compared to I
series) but more uniform strength properties over the cross-section of
the bar were noticed. Microstructure and Young-s modulus
investigations were made.
Abstract: The influence of full-fat soy flour (FFSF) and
extrusion conditions on the mechanical characteristics of dry
spaghetti were evaluated. Process was performed with screw speed of
10-40rpm and water circulating temperature of 35-70°C. Data
analysis using mixture design showed that this enrichment resulted in
significant differences in mechanical strength.
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.
Abstract: This current research focused on development of degradable starch based packaging film with enhanced mechanical properties. A series of low density polyethylene (LDPE)/tapioca starch compounds with various tapioca starch contents were prepared by twin screw extrusion with the addition of maleic anhydride grafted polyethylene as compatibilizer. Palm cooking oil was used as processing aid to ease the blown film process, thus, degradable film can be processed via conventional blown film machine. Studies on their characteristics, mechanical properties and biodegradation were carried out by Fourier Transform Infrared (FTIR) spectroscopy and optical properties, tensile test and exposure to fungi environment respectively. The presence of high starch contents had an adverse effect on the tensile properties of LDPE/tapioca starch blends. However, the addition of compatibilizer to the blends improved the interfacial adhesion between the two materials, hence, improved the tensile properties of the films. High content of starch amount also was found to increase the rate of biodegradability of LDPE/tapioca starch films. It can be proved by exposure of the film to fungi environment. A growth of microbes colony can be seen on the surface of LDPE/tapioca starch film indicates that the granular starch present on the surface of the polymer film is attacked by microorganisms, until most of it is assimilated as a carbon source.