Extrusion Dies for Plastics and Rubber - Design and Engineering Computations (4th Edition)

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 d...

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Main Authors Hopmann, Christian, Michaeli, Walter
Format eBook
LanguageEnglish
Published Chicago Hanser Publishers 2016
Hanser Publications
Hanser
Edition4
Subjects
Manufacture & Processing
Plastics & Rubber
Plastics-Extrusion
Rubber-Extrusion
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Abstract 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.
AbstractList 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.The 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).
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.
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.
Author Hopmann, Christian
Michaeli, Walter
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Snippet 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...
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...
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SubjectTerms Manufacture & Processing
Plastics & Rubber
Plastics-Extrusion
Rubber-Extrusion
TableOfContents Title Page Prefaces Table of Contents 1. Introduction 2. Properties of Polymeric Melts 3. Fundamental Equations for Simple Flows 4. Computation of Velocity and Temperature Distributions in Extrusion Dies 5. Monoextrusion Dies for Thermoplastics 6. Coextrusion Dies for Thermoplastics 7. Extrusion Dies for Elastomers 8. Heating of Extrusion Dies 9. Mechanical Design of Extrusion Dies 10. Handling, Cleaning, and Maintaining Extrusion Dies 11. Calibration of Pipes and Profiles Index
5.5.1 Designs and Applications -- 5.5.2 Design -- 5.6 Dies for Foamed Semifinished Products -- 5.6.1 Dies for Foamed Films -- 5.6.2 Dies for Foamed Profiles -- 5.7 Special Dies -- 5.7.1 Dies for Coating of Profiles of Arbitrary Cross Section -- 5.7.2 Dies for the Production of Profiles with Reinforcing Inserts -- 5.7.3 Dies for the Production of Nets -- 5.7.4 Slit Die with Driven Screw for the Production of Slabs -- 5.8 References of Chapter 5 -- 6 Coextrusion Dies for Thermoplastics -- 6.1 Designs -- 6.1.1 Externally Combining Coextrusion Dies -- 6.1.2 Adapter (Feedblock) Dies -- 6.1.3 Multimanifold Dies -- 6.1.4 Layer Multiplication Dies -- 6.2 Applications -- 6.2.1 Film and Sheet Dies -- 6.2.2 Blown Film Dies -- 6.2.3 Dies for the Extrusion of Parisons for Blow Molding -- 6.3 Computations of Flow and Design -- 6.3.1 Computation of Simple Multilayer Flow with Constant Viscosity -- 6.3.2 Computation of Coextrusion Flow by the Explicit Finite Difference Method -- 6.3.3 Computation of Velocity and Temperature Fields by the Finite Difference Method -- 6.3.4 Computation of Velocity Fields in Coextrusion Flows by FEM -- 6.4 Instabilities in Multilayer Flow -- 6.5 References of Chapter 6 -- 7 Extrusion Dies for Elastomers -- 7.1 Design of Dies for the Extrusion of Elastomers -- 7.2 Fundamentals of Design of Extrusion Dies for Elastomers -- 7.2.1 Thermodynamic Material Data -- 7.2.2 Rheological Material Data -- 7.2.3 Computation of Viscous Pressure Losses -- 7.2.3.1 Formulas for Isothermal -- 7.2.3.2 Approaches to Nonisothermal Computations -- 7.2.4 Estimation of the Peak Temperatures -- 7.2.5 Consideration of the Elastic Behavior of the Material -- 7.3 Design of Distributor Dies for Elastomers -- 7.4 Design of Slotted Disks for Extrusion Dies for Elastomers -- 7.4.1 Computation of Pressure Losses -- 7.4.2 Extrudate Swelling (Die Swell)
Intro -- Preface -- Preface to the Third Edition -- Preface to the Second Edition -- Preface to the First Edition -- Contents -- 1 Introduction -- 1.1 Reference of Chapter 1 -- 2 Properties of Polymeric Melts -- 2.1 Rheological Behavior -- 2.1.1 Viscous Properties of Melts -- 2.1.1.1 Viscosity and Flow Functions -- 2.1.1.2 Mathematical Description of the Pseudoplastic Behavior of Melts -- 2.1.1.3 Influence of Temperature and Pressure on the Flow Behavior -- 2.1.2 Determination of Viscous Flow Behavior -- 2.1.3 Viscoelastic Properties of Melts -- 2.2 Thermodynamic Behavior -- 2.2.1 Density -- 2.2.2 Thermal Conductivity -- 2.2.3 Specific Heat Capacity -- 2.2.4 Thermal Diffusivity -- 2.2.5 Specific Enthalpy -- 2.3 References of Chapter 2 -- 3 Fundamental Equations for Simple Flows -- 3.1 Flow through a Pipe -- 3.2 Flow through a Slit -- 3.3 Flow through an Annular Gap -- 3.4 Summary of Simple Equations for Dies -- 3.5 Phenomenon of Wall Slip -- 3.5.1 Model Considering the Wall Slip -- 3.5.2 Instability in the Flow Function - Melt Fracture -- 3.5 References of Chapter 3 -- 4 Computation of Velocity and Temperature Distributions in Extrusion Dies -- 4.1.1 Continuity Equation -- 4.1.2 Momentum Equations -- 4.1.3 Energy Equation -- 4.2 Restrictive Assumptions and Boundary Conditions -- 4.3 Analytical Formulas for Solution of the Conservation Equations -- 4.4 Numerical Solution of Conservation Equations -- 4.4.1 Finite Difference Method -- 4.4.2 Finite Element Method -- 4.4.3 Comparison of FDM and FEM -- 4.4.4 Examples of Computations of Extrusion Dies -- 4.5 Consideration of the Viscoelastic Behavior of the Material -- 4.6 Computation of the Extrudate Swelling -- 4.7 Methods for Designing and Optimizing Extrusion Dies -- 4.7.1 Industrial Practice for the Design of Extrusion Dies -- 4.7.2 Optimization Parameters
4.7.2.1 Practical Optimization Objectives -- 4.7.2.2 Practical Boundary Conditions and Constraints When Designing Flow Channels -- 4.7.2.3 Independent Parameters during Die Optimization -- 4.7.2.4 Dependent Parameters during Die Optimization and Their Modeling -- 4.7.3 Optimization Methods -- 4.7.3.1 Gradient-Free Optimization Methods -- 4.7.3.2 Gradient-Based Optimization Methods -- 4.7.3.3 Stochastic Optimization Methods -- 4.7.3.4 Evolutionary Methods -- 4.7.3.5 Treatment of Boundary Conditions -- 4.7.4 Practical Applications of Optimization Strategies for the Design of Extrusion Dies -- 4.7.4.1 Optimization of a Convergent Channel Geometry -- 4.7.4.2 Optimization of Profile Dies -- 4.8 References of Chapter 4 -- 5 Monoextrusion Dies for Thermoplastics -- 5.1 Dies with Circular Exit Cross Section -- 5.1.1 Designs and Applications -- 5.1.2 Design -- 5.2 Dies with Slit Exit Cross Section -- 5.2.1 Designs and Applications -- 5.2.2 Design -- 5.2.2.1 T-Manifold -- 5.2.2.2 Fishtail Manifold -- 5.2.2.3 Coathanger Manifold -- 5.2.2.4 Numerical Procedures -- 5.2.2.5 Considerations for Clam Shelling -- 5.2.2.6 Unconventional Manifolds -- 5.2.2.7 Operating Performance of Wide Slit Dies -- 5.3 Dies with Annular Exit Cross Section -- 5.3.1 Types -- 5.3.1.1 Center-Fed Mandrel Support Dies -- 5.3.1.2 Screen Pack Dies -- 5.3.1.3 Side-Fed Mandrel Dies -- 5.3.1.4 Spiral Mandrel Dies -- 5.3.2 Applications -- 5.3.2.1 Pipe Dies -- 5.3.2.2 Blown Film Dies -- 5.3.2.3 Dies for the Extrusion of Parisons for Blow Molding -- 5.3.2.4 Coating Dies -- 5.3.3 Design -- 5.3.3.1 Center-Fed Mandrel Dies and Screen Pack Dies -- 5.3.3.2 Side-Fed Mandrel Dies -- 5.3.3.3 Spiral Mandrel Dies -- 5.3.3.4 Coating Dies -- 5.4 Formulas for the Computation of the Pressure Loss in Flow Channel Geometries other than Pipe or Slit -- 5.5 Dies with Irregular Outlet Geometry (Profile Dies)
7.4.3 Simplified Estimations for the Design of a Slotted Disk -- 7.5 References of Chapter 7 -- 8 Heating of Extrusion Dies -- 8.1 Types and Applications -- 8.1.1 Heating of Extrusion Dies with Fluids -- 8.1.2 Electrically Heated Extrusion Dies -- 8.1.3 Temperature Control of Extrusion Dies -- 8.2 Thermal Design -- 8.2.1 Criteria and Degrees of Freedom for Thermal Design -- 8.2.2 Heat Balance of the Extrusion Die -- 8.2.3 Restrictive Assumptions in the Modeling -- 8.2.4 Simulation Methods for Thermal Design -- 8.3 References of Chapter 8 -- 9 Mechanical Design of Extrusion Dies -- 9.1 Mechanical Design of a Breaker Plate -- 9.2 Mechanical Design of a Die with Axially Symmetrical Flow Channels -- 9.3 Mechanical Design of a Slit Die -- 9.4 General Design Rules -- 9.5 Materials for Extrusion Dies -- 9.6 References of Chapter 9 -- 10 Handling, Cleaning, and Maintaining Extrusion Dies -- 10.1 References of Chapter 10 -- 11 Calibration of Pipes and Profiles -- 11.1 Types and Applications -- 11.1.1 Friction Calibration -- 11.1.2 External Calibration with Compressed Air -- 11.1.3 External Calibration with Vacuum -- 11.1.4 Internal Calibration -- 11.1.5 Precision Extrusion Pullforming (the Technoform Process) -- 11.1.6 Special Process with Movable Calibrators -- 11.2 Thermal Design of Calibration Lines -- 11.2.1 Analytical Computational Model -- 11.2.2 Numerical Computational Model -- 11.2.3 Analogy Model -- 11.2.4 Thermal Boundary Conditions and Material Data -- 11.3 Effect of Cooling on the Quality of the Extrudate -- 11.4 Mechanical Design of Calibration Lines -- 11.5 Cooling Dies, Process for Production of Solid Bars -- 11.6 References of Chapter 11 -- Index
Title Extrusion Dies for Plastics and Rubber - Design and Engineering Computations (4th Edition)
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