powder to profile
TRANSCRIPT
Powder to ProfileJELD-WEN Extruder Technology
Objectives
At the end of this module, you will be able to:
Break the profile equipment into sections and define the function of each piece as the PVC Compound is transformed into a profile.
Describe the status of the PVC Compound as it becomes a profile throughout the extrusion process.
OverviewPowder to Profile
Back
Extruder
Phase OnePVC Melt
Phase TwoRheology
Die Calibrator
Front
Phase ThreeEnd Product
Trouble Shooting
Haul-off
Visual Check Point – Trouble Shooting A B C D E
Phase One: Extruder & PVC Melt
PVC Compound Converted Into Fused MassPVC Compound Converted Into Fused Mass
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
CompressionCompression
Material Handling
From Rail Car to Storage Silo From Storage Silo to Day Bin From Day Bin to Vacuum Receiver Hopper
From the Vacuum Receiver Hopper,
the compound filters into the Surge Hopper
From the Surge Hopper, the compound is metered into the Extruder by the Gravimetrics hopper
11 22 33
44 55
Gravimetrics
Gravimetric unit measures, records, and controls the consumption of material into the extruder process.
GravimetricsHopper Levels
Shut-off Device
Load Cell
Stop
Receiver Fork
Weight Hopper
Collector Funnel
Impact Cone
GravimetricsReasons for Throughput Variation
- High Bulk Weight- Good Flow properties
- Low Bulk Weight- Poor Flow Properties
GravimetricsHopper Feeding the Screws Compound
Constant material flow in the feeding area of the extruder
Impact Cone
GravimetricsEffect of Throughput Variation
Weight Per Foot
Weight Per Foot
Haul-Off Speed
Haul-Off Speed
WallThickness
WallThickness
Throughput(Outlet)
Throughput(Outlet)
ScrewSpeedScrewSpeed
Throughput(Inlet)
Throughput(Inlet)
lb/ft ft/min in. lb/h RPM lb/h
GravimetricsIf Hopper Levels Drop
lb/ft Ft/min In. Lb/h RPM Lb/h
Weight Per Foot
Weight Per Foot
Haul-Off Speed
Haul-Off Speed
WallThickness
WallThickness
Throughput(Outlet)
Throughput(Outlet)
ScrewSpeedScrewSpeed
Throughput(Inlet)
Throughput(Inlet)
Gravimetrics
The compound is measured
Released on top of the screws
Heat & pressure push it through the
extruder barrel.Doser in Feed ThroatDoser in Feed Throat
Review Question
True or False
Gravimetrics measures, records, and controls the consumption of material throughputs in the extruder process.
True
Extruder: Barrel and Screws
Through the Feed Throat, the compound falls onto a set of screws that turn inside a barrel. The compound is converted into a molten state with the addition of heat & pressure.
Extruder Size: Barrel, Screws Dimensions, Number of Zones
Our conical extruder of 63mm has 4 zones
Our parallel extruder of 72 mm & 93mm have 5 zones
Phase One: Extruder & PVC MeltBarrel & Screw Zones
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Compression
Phase One: Extruder & PVC MeltBarrels and Heater Bands
Barrel, Heater Bands, & Cooling FansThe barrel is divided into sections called zonesHeater bands encircling the barrels define the zonesCooling fans
Review Questions
Answer the following question.
What is displayed in the picture below?
AnswerThe picture displays an air cooled barrel system.
Extruder: Barrel & Screws
Compression
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusion
Barrel & ScrewsParallel and Conical
Parallel ScrewsParallel Screws
Conical ScrewsConical Screws
Barrel & Screws take the powder compound, heats and mixes it into a homogeneous melt, and pushes it through the die.
Barrel & Screws take the powder compound, heats and mixes it into a homogeneous melt, and pushes it through the die.
Barrel and ScrewsParallel Screws
Molybdeum Coated ScrewsMolybdeum Coated Screws
Extruder: Barrel & Screws
Conical Two ScrewsNitrated steel-very hardOutlasts Screws’ BarrelMay be Chromed
Phase One: Extruder & PVC MeltCooling the Screw and Fused PVC
It is important to cool the tip and body of the screws to prevent sticking of the fused PVC Compound
Phase One: Extruder & PVC MeltBarrel & Screw Zones
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
CompressionCompression
Testing the Compound
Rheology: Fusion Time & Torque for JW FormulationRheology: Fusion Time & Torque for JW Formulation
Phase One: Extruder & PVC MeltFeeding Zone & Powder PVC on the Screws
Melting/ Degassing Metering/ Partial Fusing Final Fusing
Melting/ Degassing Metering/ Partial Fusing Final FusingFeedingFeeding
CompressionCompression
Phase One: Extruder & PVC MeltsGravimetrics, Feed Throat & Doser
Remember
The PVC Compound is vacuumed from the Daybin into the vacuum receiving hoppers
The compound is gravity fed from the vacuum receiving hoppers into the gravimetric
The gravimetric meters the virgin PVC, regrind & color concentrate into the Dosing Unit
Phase One: Extruder & PVC MeltsMelting/ Partial Fusing Zone
Feeding Feeding Degassing Metering/ Final Fusing
Degassing Metering/ Final Fusing
CompressionCompression
Melting/Partial Fusing
Melting/Partial Fusing
Phase One: Extruder & PVC MeltsIn-between Zone 1 & 2 Melting/ Fusion Mechanisms
Barrel
Screw
Solid Bed Interface
Pushing Flight
Melt Pool
Melt Film Trailing Edge
Dissipative Melting of Solid Bed
Phase One: Extruder & PVC MeltsIn-between Zone 1 & 2 Melting/Fusion Mechanisms
Barrel
Screw
Conductive Melting After Solid Bed Breakup
Phase One: Extruder & PVC MeltCompression Zone
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Compression
Phase One: Extruder & Raw MaterialDegassing Zone
Feeding Melting/ Metering/ Partial Fusing Final Fusing
Feeding Melting/ Metering/ Partial Fusing Final Fusing
CompressionCompression
DegassingDegassing
Phase One: Extruder & PVC MeltVacuum Port or Visual Check Point
Vacuum Port or Visual Check Point
An area to view the compound as it is being pushed through the barrel by the screw
Phase One: Extruder & PVC MeltMetering/ Final Fusing
Feeding Melting/ Degassing Partial Fusing
Feeding Melting/ Degassing Partial Fusing
CompressionCompression
Metering/Final Fusing
Metering/Final Fusing
Phase One: Extruder & PVC MeltSummary
Back Back Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing
CompressionCompression
FrontFront
Review Question
True or False
The extruder combines PVC Compound with heat and pressure to fuse the material into a unified mass.
TRUE
Phase Two: RheologyDie Calibrator
Back
Extruder
Phase OnePVC Melt Phase Two
Rheology
Phase TwoRheology
Die Calibrator
Front
Phase ThreeEnd Product
Trouble Shooting
Haul-off
Visual Check Point-Trouble Shooting A B C D E
Review Question
Fill-in-the-Blank. Use 4 of the following words.
Die, Shape, Calibrator, Water Tanks, Extruder
The purpose the Rheology Phase is to ______ the molten mass from the _______ with the hot ___ and to cool and shape the profile with the ________.
The purpose the Rheology Phase is to shape the molten mass from the extruder with the hot die and to cool and shape the profile with the calibrator.
Phase Two: RheologyThe Adaptor & Y Block
The Y-Block is attached to the extruder with an adaptor
The die box is mounted either to the Y-Block or directly to the adaptor for single strand.
Adaptor Y-Block
End of Barrel Extruder Adaptor
Phase Two: RheologyThe Adaptor & Y-Block
The adaptor funnels the melt into the die or the Y-Block
A Ring or Breaker Plate are used to align the Die Box or Y-Block to the adaptor & they also provide a sealing surface.
The breaker plate provides a resistance of the flow from the extruder.
Phase Two: RheologyThe Die
The die box is attached to the extruder adaptor or directly to the Y-block.
The die is made to slide into the die box.
There is a clamping ring which holds the die into the die box.
Review Question
Fill-in-the-Blank
The die box or “Y” block is attached to the extruder with an ____________.
The die box or “Y” block is attached to the extruder with an adaptor.
Phase Two: RheologyThe Die
The die shapes the PVC melt from the extruder into the desired shape
Review Question
Fill-in-the Blank
The purpose of the die is to _______ the _______ or extrudate from the extruder into the desired shape.
The purpose of the die is to shape the PVC Melt or extrudate from the extruder into the desired shape.
Phase Two:JELD-WEN Die Parts
Distance Distribution Mandrel Plate Entry Side
Torpedo
Mandrel Plate Exit Side
Mandrel
Compression #2 Outlet #1 Outlet Mandrel Top
Review Question
Fill-in-the Blank
The die contains the following plates:
Distance
Distribution
Torpedo and __________
______________
#2 and #1 Outlet and Mandrel Top
The die contains the following plates:• Distance • Distribution• Torpedo and Mandrel• Compression • #2 and #1 Outlet and Mandrel Top
Phase Two: RheologyMelt Rheology
The extruder fuses the material into a unified mass, called PVC melt and is exerting pressure to move it forward
Flow is how the PVC melt movesforward from the extruderthrough the die
Review Question
Fill-in-the Blank
The extruder fuses the PVC Compound into a unified mass called _______ and exerts pressure to move it forward.
The extruder fuses the PVC Compound into a unified mass called PVC Melt and exerts pressure to move it forward.
Phase Two: RheologyScience of Flow
Basic Measurements
Shear Stress
Shear Rate
Melt Temperature
Melt Viscosity
Is this a good melt?
Phase Two: RheologyStress, Rate, Temperature & Viscosity
Shear Stress =Melt Pressure
ViscosityTemperature 380º F
Temperature 360º F
Shear Rate = Screw RPM
Higher Stress + Shear Rate = More Melt Flow, Plasticity, or Viscosity
Review Question
Fill-in-the Blank
Higher Shear Stress plus Shear Rate = More Melt Flow, Plasticity or ______________
Higher Shear Stress plus Shear Rate = More Melt Flow, Plasticity or Viscosity
Phase Two: RheologyLaminar Flow: Static Wormy Polymer Chains
O PSI
Melt Temperature 385º FPolymer chains are in static form-worm like
0 Flow
Die Opening
Review Question
Fill-in-the Blank
Shear stress is another word for melt _____. Shear stress is another word for melt pressure.
Phase Two: RheologyLaminar Flow: Activation Energy
Low to Medium PSI
Activation Energy
Melt Temperature 385º FPolymer Chains
Stretching to Form Layers
0 Flow
Die Opening
Review Question
Fill-in-the Blank
Shear _____ refers to Screw RPM. Shear Rate refers to Screw RPM.
Phase Two: RheologyLaminar Flow Achievement
Medium to High PSI
Melt Temperature 385º FExceed activation energy
polymer layers slide by each other
Flow
Review Question
Fill-in-the Blank
Melt viscosity refers to the ________ of the PVC Melt exiting the die.
Melt viscosity refers to the stiffness of the PVC Melt exiting the die.
Review Question
Fill-in-the Blank
The molten plastic mass that has no Shear Stress or Shear Rate will not ______.
The molten plastic mass that has no Shear Stress or Shear Rate will not flow.
Phase Two: RheologyLaminar Flow: Melt Fracture
Increase in shear rate and/or shear stress beyond quality limits adversely effects the melt and the end product
Review Question
True or False
By decreasing shear stress and the raising of shear rate, the higher your viscosity of melt through the die.
FALSE
The higher the pressure (Shear Stress) and the higher the screw RPM (Shear Rate), the higher your viscosity or flow of your melt.
Phase Two: RheologyDie Swell
Die
Extruder
Review Question
Fill-in-the Blank
Shear Stress is the amount of energy that is being applied to the melt. Shear Stress refers to the __________ behind the die. This pressure is being generated by the __________.
Shear Stress is the amount of energy that is being applied to the melt. Shear Stress refers to the melt pressure behind the die. This pressure is being generated by the extruder.
Phase Two: RheologyCorrect Flow Properties
Flow Challenges
Poor Surface, too dull or too shiny
Pock marks
Lumps
Internal walls separating
Wavy edges
Loss of definition on edges
Erratic flow may cause jam ups
Excessive die or calibration fouling
Wall Thickness
Review Question
Fill-in-the Blank
Examples of flow challenges are:
Poor surface-too dull or too shiny
_____________
Lumps
Internal walls separating
______________
Loss of definition on edges
Erratic flow and jam ups
Examples of flow challenges are:• Poor surface-too dull or too shiny• Pock Marks• Lumps• Internal walls separating• Wavy Edges• Loss of definition on edges• Erratic flow and jam ups
Phase Two: RheologyCalibration & Water Cooling
First Calibrator
Die
Blue HosesCool Water
Red HosesWarm Water
White Hoses
Vacuum
Phase Two: Rheology#1 Calibrator Cooling
Die Swell
Cool Water In Vacuum
Vacuum Slots & Hoses
Warm Water Out
Dark Area Cooler: 125 F – 135 F
Light Area Hotter: 250º F – 350º F
Calibrator
Review Question
Fill-in-the Blank
When flow occurs in the die, it will flow the fastest in the ______ of the flow and the ________ at the wall of the flow.
When flow occurs in the die, it will flow the fastest in the center of the flow and s l o w e s t at the wall of the flow.
Phase Two: RheologyWater Tank Calibrators
Water Tank Calibrators
Series of water tanks
Sizing elements
Vacuum
Long
Numerous elements
Review Questions
Work in teams and answer the following questions.
The instructor will assign questions for you to answer.
Use your books to find the answers.
Review as a group.
Review Question
Fill-in-the Blank
The die takes the PVC Melt and refines the shape into a _______ using pressure. The calibrator continues to refine the profile by _____ it using water and a vacuum.
The die takes the PVC Melt and refines the shape into a profile using pressure. The calibrator continues to refine the profile by cooling it using water and a vacuum.
Review Question
Fill-in-the Blank
Shear Rate is the _____ at which Shear Stress (or energy) is being applied behind the die. To measure Shear Rate, use RPM of the extruder screw.
Shear Rate is the speed at which Shear Stress (or energy) is being applied behind the die. To measure Shear Rate, use RPM of the extruder screw.
Review Question
True or False
The molecules in a molten plastic mass that have flow, will have no organization and look like a cluttered mess of strings.
FALSE
Molecules in a molten plastic mass with NO FLOW will have no organization and look like a cluttered mess of strings.
Molecules WITH FLOW have organization and are stretched to form layers.
Review Question
True or False As the melt is forced to flow through the die, the
polymer strings do not stretch and remain disorganized. When the melt exits the die, the pressure is released and the polymer strings will recoil back. This is known as die swell. This is a know % for each type of compound, for PVC window profiles it is 2 – 8%.
False
As the melt is forced to flow through the die, the polymer strings do stretch.
Review Question
Fill-in-the Blank
When Shear Stress and Shear Rate are applied, the unorganized polymer molecules begin to shift into organized layers and are stretched. The amount of energy to make this happen is called, ___________ ___________.
When Shear Stress and Shear Rate are applied to a PVC Melt, the unorganized polymer molecules begin to shift into organized layers and are stretched. The amount of energy to make this happen is called, Activation Energy.
Review Question
Fill-in-the Blank
Flow is achieve by exceeding ______ Energy, forcing the polymer molecules to slide by each other. The polymer layers slide the slowest at the ____ of the die and the fastest in the _________ of the flow.
Flow is achieve by exceeding Activation Energy, forcing the polymer molecules to slide by each other. The polymer layers slide the slowest at the wall of the die and the fastest in the middle of the flow.
Review Question
True or False
If the Shear Rate and/or Shear Stress is increased beyond certain limits, the PVC Melt exiting the die can be adversely affected. Initially, one may see irregularities like pock marks and tear drop shaped lumps in the surface.
TRUE
Review Question
True or False
If the limits of Shear Rate and/or Shear Stress are increased too far, the strings of material that are stretched may break and melt fracture may occur.
True
Review Question
True or False
To get the correct flow properties there must be a balance of Shear Rate, Shear Stress, and Melt Temperature. If these are not correct, flow problems will occur.
True
Review Question
True or False
The temperature of the PVC Compound exiting the adaptor is melt temperature. This is monitored through the Operator’s Panel.
TRUE
Phase Three: End Product & Haul-off Station
Back
Extruder
Phase OnePVC Melt
Phase TwoRheology
Die Calibrator
Front
Phase ThreeHaul-Off
End Product
Haul-Off
Visual Check Points- Trouble Shooting A B C D E
Visual Check Points- Trouble Shooting A B C D E
DownstreamAncillary Equipment
Air Showers
Blow excess moisture off the profile as it moves out of the water tanks
Bow Heaters
Heaters positioned on any side of a profile to correct bow created during the cooling process
Weather Strip
Inserts the pile weather strip
Nail Fin Pinch
Punches holes in nail fin of frames
DownstreamHaul-Off Station
The Haul-Off Station pulls the profile through the calibrator, cuts the cooled profile to size, and releases it to a tilt table for packaging.
DownstreamHaul-Off
Haul-Off
Pulls the profile through the calibration system at a precise rate of speed.
Pads
DownstreamHaul-off Station - Guillotine
Guillotine
Cuts the profile to length
Phase Three: End ProductPulled by the Haul-off
Haul – Off Station
Pulls profile through the calibration process
Guillotine cuts profile to length
Moves the profile to a tilt table for storage collection
Final Visual Check Point for Quality & Trouble Shooting
Trouble Shooting 5 Visual Check Points On-the-Floor
Back
Extruder
Phase OnePVC Melt
Phase TwoRheology
Die Calibrator
Front
Phase ThreeEnd Product
Haul-off
Visual Check Points- Trouble Shooting A B C D E
Visual Check Points- Trouble Shooting A B C D E
Trouble ShootingVisual Check Point: Feed Port & Control Panel
Back
Extruder
Phase OnePVC Melt
Visual Check Point A
Feed Port&
Control Panel
Trouble ShootingVisual Check Point: Vacuum Port
Visual Check PointB
Vacuum Port
Visual Check PointB
Vacuum Port
Look for Crumbly Belt orStrip with broken edges
Back
Extruder
Phase OnePVC Melt
Trouble ShootingVisual Check Point: Melt Exiting Die to Calibrator
Phase TwoRheology
Phase TwoRheology
Die Calibrator
Visual Check Point C Melt Exiting DieEntering the Calibrator
Visual Check Point C Melt Exiting DieEntering the Calibrator
Melt, Die & Calibrator
Trouble ShootingVisual Check Point: Extrusion Exiting Water Tanks
Phase TwoRheology
Phase TwoRheology
Die Calibrator
Visual Check PointD
Extrusion Exiting Water Tanks
Visual Check PointD
Extrusion Exiting Water Tanks
Trouble ShootingVisual Check Point: Haul-Off Table
Front
Phase ThreeEnd Product
Haul-off Station
Visual Check Point E
Haul-Off Table
Visual Check Point E
Haul-Off Table
Trouble ShootingVisual Check Point: Guillotine
Front
Phase ThreeHaul-Off
End Product
Haul-off
Visual Check Point E
Haul-Off Table
Visual Check Point E
Haul-Off Table
SummaryTrouble Shooting