Extrusion Dies for Plastics & Rubber - Design & Engineering Computations.
This definitive book provides a comprehensive account of the full range of dies used for extrusion of plastics and elastomers. The distinctive features of the various types of dies are described in detail. Expert advice on the configuration of dies is given, and the possibilities of computer-aided design, as well as its limitations, are demonstrated.
Fundamentals and computational procedures are clearly explained so that no special prior knowledge of the subject is required. The mechanical configuration, handling, and maintenance of extrusion dies are described. Calibration procedures for pipes and profiles are also discussed.
This book was written for plastics engineers who need daily support in their practical work in industry and science, as well as for students preparing for their professional life.
This 4th edition is brought up to date with several important additions, including coverage of multilayer (>15 layer) dies, melt encapsulation, and simulation tools (rheological/thermal CFD simulations).
Table of Contents
PREFACE TO THE THIRD EDITION
PREFACE TO THE SECOND EDITION
PREFACE TO THE FIRST EDITION
INTRODUCTION
PROPERTIES OF POLYMERIC MELTS
Rheological Behavior
Viscous Properties of Melts
Viscosity and Flow Functions
Mathematical Description of the Pseudoplastic Behavior of
Influence of Temperature and Pressure on the Flow
Determination of Viscous Flow Behavior
Viscoelastic Properties of Melts
Thermodynamic Behavior
Density
Thermal Conductivity
Specific Heat Capacity
Thermal Diffusivity
Specific Enthalpy
FUNDAMENTAL EQUATIONS FOR SIMPLE FLOWS
Flow through a Pipe
Flow through a Slit
Flow through an Annular Gap
Summary of Simple Equations for Dies
Phenomenon of Wall Slip
Model Considering the Wall Slip
Instability in the Flow Function - Melt Fracture
COMPUTATION OF VELOCITY AND TEMPERATURE DISTRIBUTIONS IN EXTRUSION DIES
Conservation Equations
Continuity Equation
Momentum Equations
Energy Equation
Restrictive Assumptions and Boundary Conditions
Analytical Formulas for Solution of the Conservation Equations
Numerical Solution of Conservation Equations
Finite Difference Method
Finite Element Method
Comparison of FDM and FEM
Examples of Computations of Extrusion Dies
Consideration of the Viscoelastic Behavior of the Material
Computation of the Extrudate Swelling
Methods for Designing and Optimizing Extrusion Dies
Industrial Practice for the Design of Extrusion Dies
Optimization Parameters
Practical Optimization Objectives
Practical Boundary Conditions and Constraints When Designing Flow Channels
Independent Parameters during Die Optimization
Dependent Parameters during Die Optimization and Their
Optimization Methods
Gradient-Free Optimization Methods
Gradient-Based Optimization Methods
Stochastic Optimization Methods
Evolutionary Methods
Treatment of Boundary Conditions
Practical Applications of Optimization Strategies for the Design of Extrusion Dies
Optimization of a Convergent Channel Geometry
Optimization of Profile Dies
MONOEXTRUSION DIES FOR THERMOPLASTICS
Dies with Circular Exit Cross Section
Designs and Applications
Design
Dies with Slit Exit Cross Section
Designs and Applications
Design
T-Manifold
Fishtail Manifold
Coathanger Manifold
Numerical Procedures
Considerations for Clam Shelling
Unconventional Manifolds
Operating Performance of Wide Slit Dies
Dies with Annular Exit Cross Section
Types
Center-Fed Mandrel Support Dies
Screen Pack Dies
Side-Fed Mandrel Dies
Spiral Mandrel Dies
Applications
Pipe Dies
Blown Film Dies
Dies for the Extrusion of Parisons for Blow Molding
Coating Dies
Design
Center-Fed Mandrel Dies and Screen Pack Dies
Side-Fed Mandrel Dies
Spiral Mandrel Dies
Coating Dies
Formulas for the Computation of the Pressure Loss in Flow Channel Geometries other than Pipe or Slit
Dies with Irregular Outlet Geometry (Profile Dies)
Designs and Applications
Design
Dies for Foamed Semifinished Products
Dies for Foamed Films
Dies for Foamed Profiles
Special Dies
Dies for Coating of Profiles of Arbitrary Cross Section
Dies for the Production of Profiles with Reinforcing Inserts
Dies for the Production of Nets
Slit Die with Driven Screw for the Production of Slabs
COEXTRUSION DIES FOR THERMOPLASTICS
Designs
Externally Combining Coextrusion Dies
Adapter (Feedblock) Dies
Multimanifold Dies
Layer Multiplication Dies
Applications
Film and Sheet Dies
Blown Film Dies
Dies for the Extrusion of Parisons for Blow Molding
Computations of Flow and Design
Computation of Simple Multilayer Flow with Constant Viscosity
Computation of Coextrusion Flow by the Explicit Finite Difference Method
Computation of Velocity and Temperature Fields by the Finite Difference Method
Computation of Velocity Fields in Coextrusion Flows by FEM
Instabilities in Multilayer Flow
EXTRUSION DIES FOR ELASTOMERS
Design of Dies for the Extrusion of Elastomers
Fundamentals of Design of Extrusion Dies for Elastomers
Thermodynamic Material Data
Rheological Material Data
Computation of Viscous Pressure Losses
Formulas for Isothermal
Approaches to Nonisothermal Computations
Estimation of the Peak Temperatures
Consideration of the Elastic Behavior of the Material
Design of Distributor Dies for Elastomers
Design of Slotted Disks for Extrusion Dies for Elastomers
Computation of Pressure Losses
Extrudate Swelling (Die Swell)
Simplified Estimations for the Design of a Slotted Disk
HEATING OF EXTRUSION DIES
Types and Applications
Heating of Extrusion Dies with Fluids
Electrically Heated Extrusion Dies
Temperature Control of Extrusion Dies
Thermal Design
Criteria and Degrees of Freedom for Thermal Design
Heat Balance of the Extrusion Die
Restrictive Assumptions in the Modeling
Simulation Methods for Thermal Design
References of Chapter 8
MECHANICAL DESIGN OF EXTRUSION DIES
Mechanical Design of a Breaker Plate
Mechanical Design of a Die with Axially Symmetrical Flow Channels
Mechanical Design of a Slit Die
General Design Rules
Materials for Extrusion Dies
HANDLING, CLEANING, AND MAINTAINING EXTRUSION DIES
CALIBRATION OF PIPES AND PROFILES
Types and Applications
Friction Calibration
External Calibration with Compressed Air
External Calibration with Vacuum
Internal Calibration
Precision Extrusion Pullforming (the Technoform Process)
Special Process with Movable Calibrators
Thermal Design of Calibration Lines
Analytical Computational Model
Numerical Computational Model
Analogy Model
Thermal Boundary Conditions and Material Data
Effect of Cooling on the Quality of the Extrudate
Mechanical Design of Calibration Lines
Cooling Dies, Process for Production of Solid Bars
INDEX.