Met die vinnige vooruitgang van globale industrialisasie, die vraag na hoëprestasiemateriaal in die motor, elektries en elektronies, konstruksie, mediese en ander velde neem dag vir dag toe. Ingenieursplastiek, as 'n belangrike hoëprestasiemateriaal, het geleidelik tradisionele metaalmateriale en algemene plastiek in baie kerntoepassingscenario's vervang as gevolg van hul uitstekende meganiese eienskappe, hitte weerstand, weerstand teen korrosie, dimensionele stabiliteit en verwerkbaarheid. Dubbelskroef-ekstruderingstegnologie is die kernverwerkingstegnologie van ingenieursplastiekverbindings, en die werkverrigting van ekstrusietoerusting bepaal direk die kwaliteit, produksiedoeltreffendheid en toepassingseffek van ingenieursplastiekprodukte.
Ons is daartoe verbind om professionele dubbelskroef-ekstrusie-oplossings vir ingenieursplastiekverwerking te verskaf, staatmaak op ons onafhanklik ontwikkelde en vervaardigde HTS-reeks-ekstruders met hoë-wringkrag-ratkaste, wat spesiaal ontwerp is vir die verwerkingseienskappe en toepassingsbehoeftes van ingenieursplastiek. Hierdie artikel sal omvattend uitbrei oor die prestasie-eienskappe, klassifikasie, verwerkingsprobleme van ingenieursplastiek, die kernrol van dubbelskroef-ekstruderingstegnologie in ingenieursplastiekverwerking, die voordele van ons HTS-reeks-ekstruders en hul doelgerigte aanpassing by ingenieursplastiek, sowel as die spesifieke toepassingsvelde, verwerkingstegnieke en algemene probleme en oplossings. Deur gedetailleerde tegniese parameters aan te vul, verwerking van besonderhede en bedryfsaansoeksake, die artikel sal verryk word om 3000-4000 woorde, verskaffing van omvattende en professionele verwysing vir ingenieursplastiekverwerkingsondernemings, tegnici en relevante praktisyns.
1. Oorsig van Ingenieursplastiek-industrie en kernprestasie-eienskappe
1.1 Huidige situasie en ontwikkelingstendens van ingenieursplastiekbedryf
Ingenieursplastiek verwys na 'n klas plastiekmateriale wat as strukturele materiale gebruik kan word en meganiese ladings in 'n wye temperatuurreeks kan dra. In vergelyking met algemene plastiek (soos poliëtileen PE, polipropileen PP, polivinielchloried PVC), ingenieursplastiek het meer uitstekende omvattende werkverrigting, en kan voldoen aan die streng gebruiksvereistes in industriële produksie en hoë-end produk vervaardiging. In onlangse jare, aangedryf deur die opgradering van stroomaf nywerhede soos motorliggewig, elektriese en elektroniese intelligensie, en hoë-endisering van mediese toestelle, die wêreldwye ingenieursplastiekmark het 'n bestendige en vinnige groeitendens getoon.
Volgens relevante industrie data, die wêreldwye ingenieursplastiekmarkgrootte het oorskry 100 miljard Amerikaanse dollars, en dit sal na verwagting 'n saamgestelde jaarlikse groeikoers van handhaaf 7%-10% in die volgende vyf jaar. Onder hulle, Asië-Stille Oseaan is die wêreld se grootste produksie- en verbruiksmark vir ingenieursplastiek, verantwoordelik vir meer as 55% van die globale markaandeel, hoofsaaklik as gevolg van die vinnige ontwikkeling van die motor, elektriese en elektroniese nywerhede in China, Indië en ander lande, sowel as die voortdurende verbetering van industriële ondersteuningskapasiteit en tegnologiese innovasievlak. China, as die wêreld se grootste ingenieursplastiekverbruiker en -produsent, het 'n groot markaanvraag, en die jaarlikse uitset en verbruik groei teen 'n dubbelsyferkoers, veral op die gebied van nuwe energievoertuie, 5G kommunikasie, en mediese toestelle, die vraag na hoëprestasie-ingenieursplastiek toon 'n plofbare groeitendens.
Die ontwikkelingstendens van die ingenieursplastiekbedryf word hoofsaaklik in vyf aspekte weerspieël: eers, hoë werkverrigting en funksionalisering. Met die voortdurende verbetering van gebruiksvereistes in stroomaf-velde, ingenieursplastiek ontwikkel tot hoër hittebestandheid, hoër sterkte, beter slytasieweerstand en spesiale funksies (soos vlamvertraging, antistaties, antibakteriese, bestraling weerstand), om aan te pas by die harde werksomgewing van hoë temperature, hoë druk, korrosie en bestraling; tweede, liggewig en integrasie. In die motor, lugvaart en ander velde, ten einde energiebesparing en emissieverminderingsdoelwitte te bereik, ingenieursplastiek word toenemend gebruik om metaalmateriaal te vervang, en die integrasie van produkontwerp word al hoe hoër, wat die aantal dele kan verminder, vereenvoudig die produksieproses en verminder koste; derde, omgewingsbeskerming en herwinbaarheid. Met die versterking van globale omgewingsbeskermingsbeleide en die verbetering van omgewingsbeskermingsbewustheid, die ontwikkeling en toepassing van herwinbare ingenieursplastiek, bio-afbreekbare ingenieursplastiek en omgewingsvriendelike verwerkingstegnologie het die fokus van die bedryf geword, omgewingsbesoedeling wat deur plastiekafval veroorsaak word, te verminder; vierde, intelligensie en presisie van verwerkingstoerusting. Ingenieursplastiek het hoë verwerkingsprobleme en streng kwaliteitvereistes, wat hoër vereistes aan verwerkingstoerusting stel. Intelligent, presiese en doeltreffende dubbelskroef-ekstruders en outomatiese produksielyne het die hoofstroom van die bedryf geword, real-time monitering te realiseer, outomatiese parameteraanpassing en voorspellende instandhouding van die verwerkingsproses; vyfde, diversifikasie van toepassingsvelde. Ingenieursplastiek brei geleidelik uit van tradisionele motors, elektriese en elektroniese velde na nuwe energie, medies, lugvaart, konstruksie en ander opkomende velde, nuwe markruimte oopmaak.
Teen hierdie agtergrond, dubbelskroef-ekstruderingstegnologie, as die kernverwerkingstegnologie van ingenieursplastiekverbindings, het die sleutel geword om die mededingendheid van ingenieursplastiekondernemings te verbeter. Ingenieursplastiek is sensitief vir oorverhitting en hidrolitiese afbraak, en het hoë vereistes vir verwerkingstemperatuur, skuifkrag, verblyftyd en temperatuurbeheer akkuraatheid. Ons HTS-reeks-ekstruders is spesiaal ontwerp vir die verwerking van ingenieursplastiek, met hoë wringkrag, hoë spoed, presiese temperatuurbeheer en uitstekende verspreibaarheid, wat die verwerkingsprobleme van ingenieursplastiek effektief kan oplos en ondernemings kan help om hoë gehalte te bereik, doeltreffende en stabiele produksie.
1.2 Kernprestasie-eienskappe van Ingenieursplastiek
In vergelyking met algemene plastiek- en metaalmateriale, ingenieursplastiek het unieke, omvattende werkverrigting, wat hul wye toepassing in verskeie industriële velde bepaal. Die kernprestasie-eienskappe van ingenieursplastiek word hoofsaaklik in die volgende vyf aspekte weerspieël, wat ook spesiale vereistes vir hul verwerkingstegnologie en toerusting stel:
1.2.1 Uitstekende hitte- en koueweerstand
Ingenieursplastiek het 'n wye temperatuuraanpassingsreeks, wat goeie meganiese eienskappe kan handhaaf (sterkte, taaiheid, hardheid) in beide hoë en lae temperatuur omgewings. In vergelyking met algemene plastiek, wat gewoonlik hul meganiese eienskappe verloor by 80-120 ℃, meeste ingenieursplastiek kan stabiel werk by 100-250 ℃, en 'n paar spesiale ingenieursplastiek (soos LOER, PI) kan selfs werk by temperature bo 300℃. Terselfdertyd, ingenieursplastiek het ook goeie koue weerstand, wat goeie taaiheid by lae temperature kan handhaaf (onder -40 ℃), en is nie maklik tot bros breuk nie. Hierdie prestasie maak ingenieursplastiek geskik vir gebruik in moeilike temperatuur omgewings, soos motoronderdele (hoë temperatuur) en buite elektriese toerusting (lae temperatuur).
Die uitstekende hittebestandheid van ingenieursplastiek is hoofsaaklik te danke aan hul spesiale molekulêre struktuur (soos aromatiese ringe, heterosikliese ringe) en sterk intermolekulêre kragte, wat maak dat hulle nie maklik by hoë temperature smelt en ontbind nie. Egter, dit bring ook sekere probleme by verwerking mee: hoër verwerkingstemperatuur is nodig om hulle te laat smelt en plastiseer, en presiese temperatuurbeheer is nodig om termiese ontbinding te vermy.
1.2.2 Goeie korrosiebestandheid en duursaamheid
Ingenieursplastiek het uitstekende chemiese stabiliteit en weerstand teen korrosie, en is nie maklik om deur sure verroes te word nie, alkalies, soute, organiese oplosmiddels en ander chemikalieë. In vergelyking met metaal materiale, wat maklik is om te roes en te roes, ingenieursplastiek het langer lewensduur in moeilike chemiese omgewings. Byvoorbeeld, poliamied (PA) ingenieursplastiek is bestand teen die meeste organiese oplosmiddels en swak sure en alkalieë; polikarbonaat (PC) ingenieursplastiek is bestand teen korrosie deur nie-oksiderende sure en soute; polifenyleensulfied (PPS) ingenieursplastiek is bestand teen korrosie deur byna alle chemikalieë behalwe sterk oksiderende sure.
Daarby, ingenieursplastiek het goeie weerbestandheid en verouderingsweerstand, en is nie maklik om af te breek en te verouder onder die werking van sonlig nie, reën, suurstof en ander omgewingsfaktore, wat hul langtermyn stabiele gebruik in buitelug en moeilike omgewings verseker. Hierdie prestasie maak ingenieursplastiek wyd gebruik in chemiese toerusting, buite elektriese toerusting, motor buite onderdele en ander velde.
1.2.3 Maklike verwerking en hoë produksiedoeltreffendheid
In vergelyking met metaal materiale, ingenieursplastiek het die voordele van maklike verwerking, eenvoudige produksieproses en hoë produksiedoeltreffendheid. Metaalmateriaal benodig gewoonlik komplekse verwerkingsprosedures soos smee, giet, bewerking, wat hoë energieverbruik het, lae doeltreffendheid en hoë koste; terwyl ingenieursplastiek deur ekstrusie verwerk kan word, spuitgiet, blaasvorm en ander metodes, wat massaproduksie kan realiseer, die produksieproses te vereenvoudig, verminder energieverbruik en produksiekoste. Byvoorbeeld, die verwerkingsiklus van 'n ingenieursplastiek motoronderdeel deur spuitgiet is slegs 'n paar sekondes tot tientalle sekondes, terwyl die verwerkingsiklus van dieselfde metaaldeel etlike ure tot etlike dae kan neem.
Egter, ingenieursplastiek het ook sekere verwerkingsprobleme: hulle is sensitief vir oorverhitting en hidrolitiese afbraak, en is maklik om te ontbind as die verwerkingstemperatuur te hoog is of die verblyftyd te lank is; terselfdertyd, sommige ingenieursplastiek (soos PA) hoë waterabsorpsie hê, wat die verwerkingseffek en produkkwaliteit beïnvloed. Daarom, dit is nodig om professionele verwerkingstoerusting en wetenskaplike verwerkingstegnieke te gebruik om die verwerkingsgehalte te verseker.
1.2.4 Uitstekende dimensionele stabiliteit en elektriese isolasie
Ingenieursplastiek het goeie dimensionele stabiliteit, en die krimptempo is klein (gewoonlik 0.3%-1.5%) tydens verwerking en gebruik, wat die dimensionele akkuraatheid van produkte kan verseker en vervorming kan vermy. Hierdie werkverrigting is veral belangrik vir hoë-presisie-onderdele, soos elektriese verbindings, motor presisie komponente, mediese toestelle, ens. Die goeie dimensionele stabiliteit van ingenieursplastiek is hoofsaaklik te danke aan hul hoë kristalliniteit, lae waterabsorpsie (behalwe vir sommige variëteite soos PA) en sterk intermolekulêre kragte.
Daarby, meeste ingenieursplastiek het uitstekende elektriese isolasieprestasie, wat goeie isolasieprestasie in 'n wye temperatuurreeks en frekwensiereeks kan handhaaf, en is nie maklik om elektrisiteit en boog te gelei nie. Dit maak ingenieursplastiek wyd gebruik in elektriese en elektroniese velde, soos bedradingsborde, kabelbinders, koppelaars, aflos, motors en ander elektriese komponente.
1.2.5 Ligte gewig en hoë spesifieke sterkte, Uitstekende slytasieweerstand
Ingenieursplastiek het die eienskappe van ligte gewig (digtheid is 1/3-1/5 van metaal materiaal) en hoë spesifieke sterkte (sterkte per eenheid gewig is gelykstaande aan of selfs hoër as dié van metaalmateriale). Byvoorbeeld, die spesifieke sterkte van glasveselversterkte poliamied (PA66+GF30) is hoër as dié van gewone koolstofstaal, wat die gewig van produkte effektief kan verminder terwyl die meganiese werkverrigting verseker word. Hierdie prestasie is veral belangrik in die motor, lugvaart en ander velde wat liggewig en energiebesparing nastreef, wat brandstofverbruik en koolstofvrystellings kan verminder.
Terselfdertyd, ingenieursplastiek het ook uitstekende slytasie- en wrywingweerstand, en die wrywingskoëffisiënt is klein, wat gebruik kan word in die vervaardiging van slytvaste onderdele (soos ratte, laers, gly blokke) sonder bykomende smering of met minder smering, die instandhoudingskoste van produkte te verminder. Byvoorbeeld, polioksimetileen (POM) ingenieursplastiek het uitstekende slytasieweerstand en staan bekend as “plastiek staal”, wat wyd gebruik word in die vervaardiging van motorratte, elektriese komponente en ander slytvaste onderdele.
1.3 Algemene klassifikasie van ingenieursplastiek
Ingenieursplastiek kan volgens hul chemiese struktuur in verskillende tipes verdeel word, prestasievlak en toepassingsveld. Die algemene klassifikasiemetodes is soos volg, wat help om die verwerkingseienskappe en toepassingscenario's van verskillende ingenieursplastiek beter te verstaan, en toepaslike ekstrusietoerusting en verwerkingstegnieke te kies:
1.3.1 Klassifikasie volgens prestasievlak
Volgens die prestasievlak, ingenieursplastiek kan verdeel word in algemene ingenieursplastiek en spesiale ingenieursplastiek.
- Algemene Ingenieurs Plastiek: Hulle is die mees gebruikte ingenieursplastiek, met relatief volwasse produksietegnologie, matige prys en goeie omvattende werkverrigting. Die belangrikste variëteite sluit poliamied in (PA), polikarbonaat (PC), polioksimetileen (POM), poliëtileentereftalaat (PET), polibutileentereftalaat (PBT), ens. Algemene ingenieursplastiek word hoofsaaklik in motors gebruik, elektries en elektronies, huishoudelike toestelle en ander velde, soos motoronderdele, elektriese verbindings, doppe vir huishoudelike toestelle, ens.
- Spesiale Ingenieurs Plastiek: Hulle het meer uitstekende prestasie (soos hoër hittebestandheid, weerstand teen korrosie, meganiese eienskappe) as algemene ingenieursplastiek, maar die produksietegnologie is kompleks en die prys is hoog. Die hoofvariëteite sluit polifenyleensulfied in (PPS), poliëter eter ketoon (LOER), poliimied (PI), polisulfon (PSU), poliëtersulfon (PES), ens. Spesiale ingenieursplastiek word hoofsaaklik in hoëvlakvelde soos lugvaart gebruik, mediese toestelle, nuwe energie, en chemiese toerusting, soos lugvaartkomponente, mediese inplantings, hoë-temperatuurbestande elektriese komponente, ens.
1.3.2 Klassifikasie volgens chemiese struktuur
Volgens die chemiese struktuur van die molekulêre ketting, ingenieursplastiek kan in poliamied verdeel word (PA), polikarbonaat (PC), polioksimetileen (POM), poliëster (PET, PBT), polifenyleensulfied (PPS), poliëter eter ketoon (LOER), ens. Elke tipe ingenieursplastiek het sy eie unieke prestasie-eienskappe en verwerkingsvereistes:
- Poliamied (PA): Ook bekend as nylon, dit het uitstekende meganiese sterkte, slytasie weerstand, taaiheid en chemiese weerstand, maar het 'n hoë waterabsorpsie, wat die dimensionele stabiliteit beïnvloed. Algemene variëteite sluit PA6 in, PA66, PA11, PA12, ens. Dit word wyd gebruik in motoronderdele (ratte, laers, inlaatspruitstukke), elektriese verbindings, tekstielvesels, ens.
- Polikarbonaat (PC): Dit het uitstekende deursigtigheid, impak sterkte, hitteweerstand en elektriese isolasie, maar het swak slytasieweerstand en is maklik om te krap. Dit word wyd gebruik in elektriese en elektroniese velde (bedradingsborde, lampdeksels), motorvelde (koplamp lense, instrument panele), mediese velde (mediese houers), ens.
- Polioksimetileen (POM): Dit het uitstekende slytasieweerstand, wrywing weerstand, dimensionele stabiliteit en meganiese sterkte, en is nie maklik om water te absorbeer nie. Dit staan bekend as “plastiek staal” en word wyd gebruik in motoronderdele (ratte, gly blokke), elektriese komponente (skakelaars, laers), meganiese onderdele, ens.
- Polyester (PET, PBT): PET het uitstekende deursigtigheid, hittebestandheid en meganiese sterkte, en word hoofsaaklik in vesels gebruik, films, bottels en ander velde; PBT het uitstekende chemiese weerstand, elektriese isolasie en verwerkingsvloeibaarheid, en word wyd gebruik in elektriese en elektroniese velde (koppelaars, aflos), motoronderdele, ens.
- Polifenyleensulfied (PPS): Dit het uitstekende hittebestandheid (langtermyn gebruik temperatuur tot 200-220 ℃), weerstand teen korrosie, vlamvertraging en elektriese isolasie, maar het swak taaiheid. Dit word wyd gebruik in hoë-temperatuurbestande elektriese komponente, motormotoronderdele, chemiese toerusting, ens.
- Polieter-eterketoon (LOER): Dit het uitstekende omvattende werkverrigting, langtermyn gebruik temperatuur tot 250-300 ℃, goeie weerstand teen korrosie, meganiese sterkte en bioversoenbaarheid. Dit word hoofsaaklik gebruik in hoë-end velde soos lugvaart, mediese inplantings, en hoë-temperatuurbestande elektriese komponente.
1.3.3 Klassifikasie volgens toepassingsveld
Volgens die aansoekveld, ingenieursplastiek kan in motor-graad ingenieursplastiek verdeel word, elektriese-graad ingenieursplastiek, mediese-graad ingenieursplastiek, lugvaart-graad ingenieursplastiek, ens. Verskillende toepassingsvelde het verskillende vereistes vir die werkverrigting van ingenieursplastiek. Byvoorbeeld, motor-graad ingenieursplastiek vereis goeie hitte weerstand, impaksterkte en weerbestandheid; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, low weight and high strength.
2. Core Processing Technology of Engineering Plastics: Twin-Screw Extrusion Technology
Engineering plastics processing mainly includes extrusion, spuitgiet, blaasvorming, molding and other methods, among which twin-screw extrusion technology is the core technology for the production of engineering plastic compounds (such as modified engineering plastics, reinforced engineering plastics) and semi-finished products (soos pype, velle, vesels). Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong shearing force, goeie meng-effek, presiese temperatuurbeheer, short residence time and strong adaptability to raw materials, wat die verwerkingsprobleme van ingenieursplastiek effektief kan oplos (soos sensitiwiteit vir oorverhitting en hidrolitiese afbraak, swak mengeffek, lae verwerkingsdoeltreffendheid) en verseker die kwaliteit van ingenieursplastiekprodukte.
2.1 Verwerkingsprobleme van ingenieursplastiek en vereistes vir ekstrusietoerusting
Soos vroeër genoem, ingenieursplastiek het uitstekende omvattende werkverrigting, maar hul verwerkingsmoeilikheid is ook hoër as dié van algemene plastiek, hoofsaaklik as gevolg van hul spesiale molekulêre struktuur en prestasie-eienskappe. Die belangrikste verwerkingsprobleme van ingenieursplastiek en die ooreenstemmende vereistes vir ekstrusietoerusting is soos volg:
2.1.1 Sensitiwiteit vir oorverhitting en hidrolitiese afbraak
Die meeste ingenieursplastiek (soos PA, PBT, PPS) is sensitief vir oorverhitting en hidrolitiese degradasie. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, which will reduce the mechanical properties, heat resistance and other performance of the product, and even cause discoloration, carbonization and other defects. Daarby, sommige ingenieursplastiek (soos PA) hoë waterabsorpsie hê, and the moisture in the material will cause hydrolytic degradation during the high-temperature processing process, affecting the product quality.
This puts forward two key requirements for extrusion equipment: eers, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, and the temperature control precision should reach ±1℃; tweede, kort verblyftyd, which can reduce the time that the material stays in the extruder barrel, avoid thermal decomposition and hydrolytic degradation. Twin-screw extruders have the advantages of short residence time (gewoonlik 1-5 minute) en presiese temperatuurbeheer, which are more suitable for engineering plastics processing than single-screw extruders (verblyftyd 5-10 minute).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (soos glasvesel, koolstofvesel, talk, vlamvertragers, versoenbaar maak) to improve the performance of the product (such as reinforcing, toughening, vlamvertrager). Byvoorbeeld, adding glass fiber to PA can improve its strength and dimensional stability; adding flame retardants to PBT can improve its flame retardancy. The uniform mixing and dispersion of modifiers in the engineering plastic matrix is crucial to the performance of the final product. If the mixing and dispersing effect is poor, the modifiers will agglomerate, resulting in uneven performance of the product, and even reduce the mechanical properties of the product.
This requires the extrusion equipment to have strong shearing force and mixing capacity. Twin-screw extruders adopt intermeshing co-rotating or counter-rotating twin-screw structure, and the relative movement between the screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the engineering plastic matrix, and ensure the mixing and dispersing effect. Daarby, the modular design of the twin-screw can freely combine different screw elements (soos om elemente oor te dra, vermenging van elemente, skeer elemente) according to the type of engineering plastic and modifier, further improving the mixing and dispersing effect.
2.1.3 High Requirements on Wear Resistance of Equipment
In die verwerking van versterkte ingenieursplastiek (soos glasveselversterkte PA, koolstofvesel versterkte PPS), die bygevoegde glasvesel, koolstofvesel en ander wysigers het 'n hoë hardheid, wat ernstige slytasie aan die skroef en loop van die ekstruder tydens die ekstrusieproses sal veroorsaak. As die skroef en loop swak slytweerstand het, hulle sal vinnig gedra word, wat lei tot verminderde skuifkrag en mengvermoë van die ekstruder, die kwaliteit van die produk beïnvloed en die dienslewe van die toerusting verminder.
Dit vereis dat die skroef en loop van die ekstruder gemaak word van hoë kwaliteit slytvaste materiale en verwerk word deur gevorderde vervaardigingstegnologie. Ons HTS-reeks-ekstruders gebruik ingevoerde slytvaste legeringstaal vir die skroef en vat, and undergo bimetallic composite treatment or laser cladding treatment, which greatly improves the wear resistance and corrosion resistance of the screw and barrel, and can adapt to the processing of reinforced engineering plastics with high hardness modifiers.
2.1.4 High Requirements on Processing Fluidity and Pressure Control
Some engineering plastics (such as PPS, LOER) have high viscosity and poor processing fluidity, which require the extruder to have strong conveying capacity and pressure control capacity to ensure the smooth progress of extrusion. If the conveying capacity is insufficient or the pressure control is unstable, it will cause uneven extrusion speed, unstable product size, and even equipment blockage.
Twin-screw extruders have strong conveying capacity and stable pressure control capacity. The intermeshing of the twin screws can generate strong pumping force, which can effectively convey high-viscosity engineering plastic materials; terselfdertyd, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, wat die interaksie van veelvuldige faktore soos temperatuur behels, druk, skuifkrag en tyd. The core purpose is to melt and plasticize the engineering plastic raw materials and modifiers, mix them uniformly, and then extrude them into the required shape (such as particles, pype, velle, vesels) through the die head. Die spesifieke werkbeginsel en prosesvloei is soos volg:
2.2.1 Raw Material Pretreatment
Raw material pretreatment is the foundation of engineering plastics extrusion processing, which directly affects the processing effect and product quality. The raw materials of engineering plastics mainly include engineering plastic resin (soos PA, PC, POM), modifiers (soos glasvesel, koolstofvesel, talk, vlamvertragers), versoenbaar maak, lubricants and other additives. The pretreatment steps are as follows:
- Drying Treatment: Die meeste ingenieursplastiek (soos PA, PBT, PPS) hoë waterabsorpsie hê, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, cracks, reduced mechanical properties). Daarom, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of engineering plastic: byvoorbeeld, PA6 is dried at 80-100℃ for 4-6 ure, PA66 is dried at 100-120℃ for 6-8 ure, PBT is dried at 120-140℃ for 2-4 ure, PPS is dried at 150-160℃ for 3-5 ure. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: Volgens die formule verhouding, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. Die mengspoed is oor die algemeen 800-1200 rpm, en die mengtyd is 5-10 minute. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (soos glasvesel), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 gaas.
2.2.2 Voer en vervoer
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. Die toevoertoestel van die ekstruder is gewoonlik toegerus met 'n frekwensie-omskakelingspoedreguleringsfunksie, which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding. The feeding hopper is also equipped with a drying device to prevent the raw materials from absorbing moisture again during feeding.
2.2.3 Smelt, Mixing and Shearing
Die materiaal wat die ekstrusieholte van die dubbelskroef-ekstruder binnegaan, word voortdurend deur die roterende skroewe vorentoe gedruk. Die ekstrusieholte bestaan uit 'n skroef en 'n loop, en die volume van die ekstrusieholte neem geleidelik langs die asrigting af. Wanneer die skroewe draai, die materiaal word geleidelik saamgepers onder die werking van die skroewe en die loop, en die druk in die ekstrusieholte neem geleidelik toe (generally 5-15MPa).
Terselfdertyd, die materiaal word aan sterk skuifkrag en wrywingskrag onderwerp wat deur die relatiewe beweging tussen die skroewe en die loop gegenereer word, asook tussen die skroefvlugte. The shear force and friction force can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the melted engineering plastic resin, and promote the fusion and compatibility between the modifier and the resin. Die wrywingskrag kan ook 'n sekere hoeveelheid hitte genereer, wat gekombineer word met die eksterne verhitting van die loop (elektriese verwarming of stoom verwarming) to make the engineering plastic resin gradually melt and plasticize.
Die loop van die ekstruder word gewoonlik verdeel in 4-6 temperatuurbeheerafdelings (voeding afdeling, smeltafdeling, mengafdeling, homogeniserende afdeling, die kopgedeelte), and the temperature of each section is precisely controlled according to the type of engineering plastic. Byvoorbeeld, when processing PA66+GF30 (glass fiber reinforced PA66), the temperature of the feeding section is 120-140℃, the melting section is 250-260℃, the mixing section is 260-270℃, the homogenizing section is 250-260℃, and the die head section is 240-250℃. The precise temperature control can ensure that the resin is fully melted without thermal decomposition, and the modifiers are uniformly dispersed.
2.2.4 Extrusion and Shaping
Die ten volle gesmelt, gemengde en verspreide materiaal word deur die skroewe na die matryskop van die ekstruder gedruk. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (korrels), the die head is equipped with multiple circular die holes (the number and size of die holes are determined according to the particle size of the granules); for the production of pipes, velle, vesels, the die head is designed into corresponding shapes (such as circular die for pipes, flat die for sheets).
The material is extruded from the die head at a high speed to form continuous semi-finished products (such as strips for granules, pype, velle). Die temperatuur van die matryskop is effens laer as dié van die homogeniserende gedeelte, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, en die afkoeltyd is 2-5 minute; for pipes and sheets, air cooling or water spray cooling is used, and the cooling speed should be controlled to avoid product deformation due to uneven cooling. Rapid cooling can make the semi-finished products solidify quickly, maintain the shape and size of the products, and improve the mechanical properties of the products.
2.2.6 Cutting and Post-Processing
Na afkoeling en stolling, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (korrels), the cooled strips are sent to a granulator for cutting, and the granulator is equipped with a rotary knife, which can cut the strips into granular products with uniform size (die deeltjiegrootte is oor die algemeen 2-5 mm, wat aangepas kan word volgens klantbehoeftes). For the production of pipes and sheets, the cooled semi-finished products are cut into the required length through a cutting machine; for the production of fibers, the cooled filaments are drawn and wound to form fiber products.
Daarby, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (such as too large, too small or agglomerated particles); the inspection step is to detect the performance (such as mechanical strength, hitte weerstand, dimensionele akkuraatheid) of the product to ensure that it meets the customer’s requirements; the packaging step is to package the qualified product in a sealed and moisture-proof manner to prevent the product from absorbing moisture and affecting the quality.
2.3 Key Factors Affecting Engineering Plastics Twin-Screw Extrusion Effect
The effect of twin-screw extrusion directly affects the quality and performance of engineering plastic products. There are many factors affecting the extrusion effect, hoofsaaklik grondstofeienskappe ingesluit, formule verhouding, voorafmeng effek, ekstrusie parameters en die kop struktuur. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.
2.3.1 Raw Material Characteristics
The type, particle size, moisture content and purity of raw materials have a great impact on the extrusion effect. Byvoorbeeld, the particle size of engineering plastic resin and modifiers should be uniform; if the particle size is uneven, it will lead to uneven melting and mixing of materials. The moisture content of raw materials must be strictly controlled below 0.1%-0.2%; as die voginhoud te hoog is, it will cause hydrolytic degradation of the material and bubbles in the product. Die suiwerheid van grondstowwe is ook baie belangrik; onsuiwerhede in grondstowwe (such as metals, stones, stof) will not only affect the product quality, maar dra ook die skroef en loop van die ekstruder, en selfs toerusting verstopping veroorsaak.
2.3.2 Formule verhouding
The formula ratio of engineering plastic compounds (the ratio of resin, modifiers and additives) is the key to determining the performance of the product. The type and dosage of modifiers should be determined according to the performance requirements of the product. Byvoorbeeld, byvoeging 20%-40% of glass fiber to PA can significantly improve its strength and dimensional stability, but excessive glass fiber will reduce the toughness and processing fluidity of the product. Die tipe en dosis bymiddels moet ook redelik ooreenstem: compatibilizers can improve the compatibility between modifiers and resin, and the dosage is generally 0.5%-2%; lubricants can reduce the friction between materials and equipment, verbeter verwerkingsvloeibaarheid, and the dosage is generally 0.3%-1%; antioxidants can prevent the material from thermal oxidation degradation during processing, and the dosage is generally 0.1%-0.5%.
2.3.3 Voormeng effek
Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. As die voormenging ongelyk is, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, uneven mixing of materials during extrusion, and reduced product performance. Om die voorafmeng effek te verseker, dit is nodig om die mengspoed te beheer, mengtyd en mengtemperatuur: the mixing speed is 800-1200 rpm, die mengtyd is 5-10 minute, en die mengtemperatuur word op 40-60 ℃ beheer (toepaslike temperatuur kan die adhesie van bymiddels verbeter en eenvormige vermenging bevorder).
2.3.4 Ekstrusie parameters
Extrusion parameters are the most important factors affecting the extrusion effect, hoofsaaklik skroefspoed ingesluit, ekstrusie temperatuur en ekstrusie druk.
- Skroef spoed: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 aan 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. Hoe hoër die skroefspoed, hoe groter die skuifkrag en wrywingskrag wat deur die materiale ontvang word, the better the mixing and dispersing effect of modifiers, en hoe hoër die produksiedoeltreffendheid. Egter, as die skroefspoed te hoog is, die verblyftyd van die materiaal in die ekstrusieholte is te kort, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; as die skroefspoed te laag is, die skuifkrag en wrywingskrag is onvoldoende, the modifiers cannot be fully dispersed, en die produksiedoeltreffendheid is laag. The screw speed should be adjusted according to the type of engineering plastic and the type of modifier: for high-viscosity engineering plastics (such as PPS, LOER), a lower screw speed is needed to ensure sufficient melting and mixing; for reinforced engineering plastics (soos glasveselversterkte PA), a higher screw speed is needed to ensure the uniform dispersion of glass fiber.
- Ekstrusie temperatuur: The extrusion temperature is the key to ensuring the melting and plasticization of engineering plastics. The temperature of each section of the barrel and die head must be precisely controlled according to the type of engineering plastic. Die temperatuur van die voerafdeling is laer (slightly higher than the drying temperature of the raw materials), wat hoofsaaklik is om te verhoed dat die materiaal koek en gladde voeding verseker; die temperatuur van die smeltgedeelte is medium, which is mainly to promote the melting and plasticization of the resin; die temperatuur van die menggedeelte is hoër, wat hoofsaaklik is om die skuif- en mengeffek te verbeter, and promote the uniform dispersion of modifiers; die temperatuur van die homogeniserende gedeelte is effens laer as die menggedeelte, wat hoofsaaklik is om die eenvormige temperatuur en viskositeit van die materiale te verseker, en vermy termiese ontbinding; die temperatuur van die matryskopgedeelte is effens laer as die homogeniserende gedeelte, which is to ensure the shaping effect of the semi-finished products. The temperature control precision should reach ±1℃ to avoid local overheating and thermal decomposition of the material.
- Ekstrusie druk: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. Die druk in die ekstrusieholte word hoofsaaklik deur die kompressieverhouding van die skroef bepaal, die matrysgatgrootte en die skroefspoed. Hoe hoër die ekstrusiedruk, the better the mixing and dispersing effect of materials, and the denser the product. Egter, as die druk te hoog is, dit sal die energieverbruik en slytasie van die toerusting verhoog, en selfs die dobbelsteenkop laat blokkeer; as die druk te laag is, die materiale kan nie ten volle saamgepers en gemeng word nie, the product is loose, en die prestasie is onstabiel. The extrusion pressure should be adjusted according to the type of engineering plastic and the shape of the product: for high-viscosity materials and products with small die holes, a higher extrusion pressure is needed.
2.3.5 Die Hoofstruktuur
The die head structure mainly includes the shape, size and number of die holes, which directly affects the shaping effect and quality of the product. For the production of engineering plastic compounds (korrels), the die head should be equipped with multiple uniform die holes, and the size of the die holes should be matched with the particle size of the product; for the production of pipes and sheets, the die head should be designed according to the shape and size of the product, and the flow channel of the die head should be smooth to avoid material accumulation and local overheating. The die head should also be equipped with a temperature control device to ensure the uniform temperature of the die head and the stable shaping of the product.
3. Our HTS Series Extruders: Professional Solutions for Engineering Plastics Processing
Ons is lankal besig met die navorsing, development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, hoë viskositeit) and application needs, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, perfectly adapting to the processing needs of various engineering plastics.
3.1 Core Advantages of HTS Series Extruders for Engineering Plastics Processing
3.1.1 High Torque and High Speed, Hoë produksie doeltreffendheid
Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS series and HTS SUPER series) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, which is much higher than that of ordinary twin-screw extruders (general torque is 8-12Nm/cm³). The high torque design ensures that the extruder can stably convey high-viscosity engineering plastic materials, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
Terselfdertyd, the HTS series extruders have a high speed design, with a maximum speed of up to 1000rpm. The high speed can generate strong shear force and mixing force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the resin matrix, and improve the mixing and dispersing effect. Daarby, the high speed design also greatly improves the production efficiency: in vergelyking met gewone ekstrueerders, the production efficiency of HTS series extruders can be increased by 30%-50%, which can meet the large-scale production needs of engineering plastics enterprises.
3.1.2 Short Residence Time, Effectively Avoiding Thermal Degradation
As engineering plastics are sensitive to overheating and hydrolytic degradation, the residence time of materials in the extruder is crucial. Our HTS series extruders adopt an optimized screw structure and barrel design, with a short residence time of only 1-3 minute, which is much shorter than that of ordinary twin-screw extruders (5-10 minute) and single-screw extruders (10-15 minute). The short residence time can effectively reduce the contact time between the material and high temperature, avoid thermal decomposition and hydrolytic degradation of the material, and ensure the mechanical properties and heat resistance of the product.
Daarby, the screw of the HTS series extruders adopts a modular design, and different screw elements can be freely combined according to the type of engineering plastic, which can further adjust the residence time of the material, ensuring that different types of engineering plastics can obtain the optimal residence time during processing.
3.1.3 Precise Temperature Control, Stable Performance
The HTS series extruders adopt an advanced intelligent temperature control system, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control precision can reach ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating and thermal decomposition of the material. The temperature control system is equipped with a real-time monitoring and alarm function: if the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and even automatically adjust the heating power or shut down the equipment if necessary, to avoid equipment failure and product quality problems.
Daarby, the barrel of the HTS series extruders adopts a double-layer jacket design, which can realize rapid heating and cooling, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 Excellent Mixing and Dispersing Effect
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, met 'n redelike skroefspoed, lood en kompressieverhouding ontwerp. Die ineenskakeling en rotasie van die tweelingskroewe kan sterk skuifkrag en kniekrag genereer, which can fully break the agglomerates of modifiers (soos glasvesel, koolstofvesel, talk), make the modifiers uniformly dispersed in the engineering plastic resin matrix, and ensure the mixing and dispersing effect. The mixing uniformity of the HTS series extruders can reach more than 95%, which is much higher than that of ordinary twin-screw extruders (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (soos om elemente oor te dra, vermenging van elemente, skeer elemente) can be freely combined according to the type of engineering plastic and modifier. Byvoorbeeld, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (such as PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 High Wear Resistance, Long Service Life
In die verwerking van versterkte ingenieursplastiek (soos glasveselversterkte PA, koolstofvesel versterkte PPS), the added modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder. Our HTS series extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.
The screw and barrel of the HTS series extruders are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) and ≥70 HRC (HTS PLUS series and HTS SUPER series), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness modifiers. This greatly extends the service life of the screw and barrel: the service life of the screw and barrel of the HTS series extruders is 2-3 times that of ordinary extruders, reducing the frequency of component replacement and the maintenance cost of the equipment.
Daarby, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, verseker dat kliënte slegs komponente vervang wanneer nodig, onnodige vermorsing te vermy.
3.1.6 Wye toepassingsreeks, Strong Flexibility
The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (PA, PC, POM, PET, PBT) and special engineering plastics (PPS, LOER, PSU, PES). The extruders can also adapt to the processing of various modified engineering plastics, such as reinforced engineering plastics (glass fiber reinforced, carbon fiber reinforced), toughened engineering plastics, flame-retardant engineering plastics, antistatic engineering plastics, ens.
The modular design of the HTS series extruders (skroef, vat, kop dood, ens.) maak die vervanging van komponente geriefliker en vinniger. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, hulle hoef net die ooreenstemmende komponente te vervang, sonder om die hele toerusting te vervang, wat die koste van toerustingtransformasie verminder en die buigsaamheid en aanpasbaarheid van die toerusting verbeter. Daarby, the HTS series extruders can also be matched with different auxiliary equipment (soos hoëspoedmengers, droërs, koelers, granuleerders, siftingsmasjiene, verpakking masjiene) to form a complete automatic production line, deurlopende produksie van grondstofvoorbehandeling tot produkverpakking te realiseer.
3.1.7 Intelligent Control, Maklike werking en instandhouding
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, wat eenvoudig en intuïtief is, maklik om te bedryf. Die stelsel kan verskeie stelle produkformules en verwerkingsparameters stoor. When customers produce different types of engineering plastics, hulle hoef net die ooreenstemmende formule en parameters te noem, sonder herhaalde ontfouting, wat tyd bespaar en produksiedoeltreffendheid verbeter.
Die stelsel is ook toegerus met 'n intydse moniteringsfunksie, wat die sleutelparameters van die ekstrusieproses kan monitor (soos temperatuur, druk, skroef spoed, voeding spoed) in reële tyd, en teken die produksiedata aan (soos uitset, verwerkingstyd) vir latere navrae en ontleding. Vir die HTS SUPER reeks ekstrueerders, ons verskaf ook 'n wolkbeheerfunksie, wat afgeleë parameteraanpassing kan realiseer, produksiedatamonitering en voorspellende instandhouding van toerusting, intelligente produksiebestuur te realiseer.
Daarby, the HTS series extruders adopt a reasonable structural design, wat die onderhoud geriefliker maak. Die skroef, vat, die kop en ander komponente kan vinnig uitmekaar gehaal en gemonteer word, wat die onderhoudstyd en arbeidsintensiteit verminder. Ons na-verkope diens span sal professionele installasie verskaf, ingebruikneming en opleidingsdienste vir kliënte, verseker dat kliënte die toerusting glad kan gebruik.
3.2 HTS Series Extruder Product Types and Their Adaptation to Engineering Plastics
In order to meet the diverse processing needs of engineering plastics enterprises of different scales and product types, we have launched three main product types in the HTS series: HTS BASIC series, HTS PLUS series and HTS SUPER series. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.
3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, lae geraas, high efficiency and long service life. The medium-torque design (specific torque 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, PET, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
In terme van strukturele ontwerp, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type of engineering plastic. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. The extruder is equipped with a PLC control system and a touch screen operation interface, which can realize automatic feeding, automatic temperature control, automatic pressure control and automatic cutting, and is simple and easy to operate.
The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized engineering plastics processing enterprises that mainly produce general engineering plastics and low-to-medium modified engineering plastics. Een van die grootste voordele van hierdie reeks is dat dit buigsame opsies kan bied deur verskillende konfigurasiekombinasies. Kliënte kan verskillende skroefelemente kies, sterf koppe, voeding toestelle, droogtoestelle en naverwerkingstoerusting volgens hul eie produktipes, produksievermoë en begroting, om 'n produksielyn te vorm wat geskik is vir hul eie behoeftes. The HTS BASIC series extruders have a reasonable price, which can help enterprises reduce the initial investment cost.
3.2.2 HTS PLUS-reeks-ekstruders: High-Performance Choice for Engineering Plastics and Modified Products
Die HTS PLUS-reeks-ekstruders gebruik hoë-wringkrag-ratkaste wat onafhanklik deur ons ontwikkel en vervaardig is, with a specific torque of 14Nm/cm³, which has stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～800 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (surface hardness ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, koolstofvesel versterkte PPS) and high-hardness modifiers. The extruder is equipped with an advanced intelligent temperature control system and a high-precision pressure sensor, which can realize precise control of extrusion parameters and real-time monitoring of production data, ensuring the stability of the extrusion process and the quality of the product.
The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER-reeks-ekstruders: Top-End Choice for High-End Engineering Plastics
Die HTS SUPER-reeks-ekstruders neem die nuutste ultra-hoë wringkrag-oordragtoestel aan wat onafhanklik deur ons ontwikkel is, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Gemik op die hoë wringkrag en hoë spoed eienskappe van hierdie reeks, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (soos LOER, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, hoë werkverrigting en intelligensie.
The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～1000 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, wat uiters hoë slytasieweerstand en korrosiebestandheid het (surface hardness ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. Die ekstruder is toegerus met 'n intelligente PLC + wolk aanraakskerm beheer stelsel, wat afgeleë parameteraanpassing kan realiseer, production data monitoring, predictive maintenance of equipment and data analysis, intelligente produksiebestuur te realiseer.
Die produksiekapasiteit van die HTS SUPER-reeks-ekstruders wissel van 1000kg/h tot 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. Hierdie reeks ekstrueerders het die voordele van hoë presisie, sterk aanpassing, multifunksie en stabiele werkverrigting, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minute) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Daarby, the HTS SUPER series extruders can also be customized according to the special processing needs of customers, providing personalized solutions.
3.3 Selection Suggestions for Engineering Plastics Extruders
When selecting twin-screw extruders for engineering plastics processing, enterprises need to comprehensively consider their own production needs, product types, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. The following are some specific selection suggestions:
3.3.1 Determine the Extruder Series According to the Type of Engineering Plastics
Different types of engineering plastics have different processing requirements, which determine the selection of extruder series. For general engineering plastics (PA6, PA66, POM, PET, PBT) with low modification degree (filling amount ≤30%), the HTS BASIC series is sufficient to meet the processing needs. Its medium torque and flexible configuration can balance processing effect and cost, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (vul hoeveelheid 30%-50%, soos glasveselversterkte PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (such as PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (LOER, PI, PSU, PES) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), the HTS SUPER series must be selected. Its ultra-high torque, maximum 1000rpm speed and fully optimized key structure can cope with the high viscosity, high temperature resistance and strict processing requirements of high-end materials, avoid thermal decomposition and material degradation, and ensure the high performance of the final product.
3.3.2 Determine the Screw Diameter and Production Capacity According to the Processing Scale
The screw diameter of the twin-screw extruder directly determines the production capacity, and enterprises need to select the appropriate screw diameter according to their own production scale and order demand. For small-scale production (100kg/h – 500kg/h), such as small-batch customization, product research and development or small orders, the HTS BASIC series with screw diameter of 30mm – 65mm is suitable; for medium-scale production (500kg/h – 2000kg/h), such as mass production of general modified engineering plastics, the HTS PLUS series with screw diameter of 65mm – 110mm can meet the demand; vir grootskaalse produksie (1000kg/h – 3000kg/h), such as large-scale production of high-end special engineering plastics or large orders from downstream enterprises, the HTS SUPER series with screw diameter of 80mm – 130mm is the best choice. It should be noted that when selecting, enterprises should not blindly pursue large production capacity. They should also consider the fluctuation of order quantity. If the order quantity is unstable, they can choose equipment with adjustable speed and flexible production capacity (such as HTS BASIC series with frequency conversion speed regulation function) to avoid waste of equipment resources and energy.
3.3.3 Consider the Modification Demand and Mixing Effect
If the enterprise’s main products are modified engineering plastics, the mixing and dispersing effect of the extruder is the key factor to be considered. For products that need to add a variety of modifiers (such as flame retardants, versoenbaar maak, reinforcing agents) terselfdertyd, it is necessary to select extruders with excellent mixing performance, such as HTS PLUS series and HTS SUPER series with modular mixing screw elements. These two series can freely combine conveying elements, mixing elements and shearing elements according to the type of modifier, adjust the mixing intensity and residence time, and ensure that various modifiers are uniformly dispersed in the resin matrix. Byvoorbeeld, when processing flame-retardant modified PBT, more mixing elements can be configured to ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. Daarby, if the enterprise has the demand of multi-variety and small-batch modification, it is recommended to select the extruder with quick replacement of screw elements (such as the modular screw design of HTS series), which can reduce the time of equipment adjustment and improve production efficiency.
3.3.4 Consider the Cost Budget and Comprehensive Benefits
Cost budget is an important factor for enterprises to select equipment, but it is not advisable to pursue low cost blindly. It is necessary to balance the initial purchase cost, later maintenance cost, energy consumption and production efficiency to maximize the comprehensive benefits. The HTS BASIC series has the lowest initial purchase cost, low energy consumption and simple maintenance, which is suitable for enterprises with limited budget and small production scale; the HTS PLUS series has a moderate initial purchase cost, but its high production efficiency, long service life and stable processing effect can reduce the later maintenance cost and improve product qualification rate, which is suitable for medium and large-sized enterprises with certain budget and pursuit of high performance; the HTS SUPER series has the highest initial purchase cost, but it can process high-end products with high added value, and its intelligent control and long service life can reduce labor cost and maintenance cost in the later period, which is suitable for large-scale enterprises with sufficient budget and focus on high-end market. Daarby, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, insluitend installasie, ingebruikneming, tegniese opleiding, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.
3.3.5 Consider the Compatibility with Auxiliary Equipment
Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, high-speed mixer, cooler, granulator, screening machine, packaging machine, ens. When selecting the extruder, enterprises need to consider the compatibility between the extruder and auxiliary equipment to ensure the smooth operation of the entire production line. Our HTS series extruders can be perfectly matched with various standard auxiliary equipment, and can also be customized according to the enterprise’s existing auxiliary equipment to avoid the waste caused by the incompatibility between new equipment and old auxiliary equipment. Byvoorbeeld, if the enterprise already has a high-speed mixer with a mixing capacity of 500kg, it can select the HTS PLUS series extruder with a production capacity of 500kg/h – 800kg/h to match it, ensuring the coordination of raw material premixing and extrusion production.
4. Application Fields of Engineering Plastics and Matching HTS Series Extruder Solutions
Ingenieursplastiek, with their excellent comprehensive performance, have been widely used in automotive, elektries en elektronies, medies, lugvaart, chemiese, construction and other fields. Different application fields have different requirements on the performance of engineering plastic products, which also puts forward different requirements on extrusion processing equipment. Hieronder, we will elaborate on the application characteristics of engineering plastics in major fields and the matching HTS series extruder solutions, providing targeted reference for enterprises in different fields.
4.1 Automotive Field: Liggewig, High Temperature Resistance and Wear Resistance
With the development of automotive lightweight and energy-saving and emission-reduction, engineering plastics have become an important material for automotive parts, gradually replacing traditional metal materials. The engineering plastics used in the automotive field mainly include PA, POM, PC, PBT, PPS, ens., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: liggewig, high temperature resistance, slytasie weerstand, dimensional stability and low VOC (vlugtige organiese verbindings), which require the extruder to have precise temperature control, excellent mixing and dispersing effect and stable production capacity.
For automotive interior parts (such as instrument panels, deurpanele, air ducts) made of general engineering plastics (PA6, POM, PC/ABS alloy), the HTS BASIC series extruders can meet the processing needs. Its flexible configuration can adjust the processing parameters according to the performance requirements of interior parts, ensure the smooth surface and dimensional stability of the product, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66+GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (LOER, PI), the HTS SUPER series extruders are required. Its ultra-high torque, precise temperature control and short residence time can avoid thermal decomposition of high-temperature resistant materials, ensure the insulation performance and corrosion resistance of the product, and meet the strict requirements of new energy vehicles on parts performance.
Gevallestudie: A large automotive parts manufacturer specializing in new energy vehicle battery parts selected our HTS SUPER series extruders (screw diameter 100mm) to process carbon fiber reinforced PEEK battery shells. The PEEK material has high viscosity and high temperature resistance, and the carbon fiber filling amount reaches 40%, which has extremely high requirements on extrusion equipment. The HTS SUPER series extruders, with their ultra-high torque of 14Nm/cm³ and maximum speed of 1000rpm, generate strong shear force and mixing force, which makes the carbon fiber uniformly dispersed in the PEEK matrix; the precise temperature control system (precision ±1℃) strictly controls the processing temperature at 380-400℃, avoiding thermal decomposition of PEEK; the short residence time (1.5 minute) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% aan 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Electrical Insulation, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Engineering plastics are mainly used in electrical connectors, bedradingsborde, aflos, motors, kabelbinders, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, vlamvertraging, dimensionele stabiliteit, corrosion resistance and low toxicity, which require the extruder to have precise temperature control, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, koppelaars) made of general engineering plastics (PA6, PBT, PC), the HTS BASIC series extruders are suitable. Its flexible configuration can match different die heads to produce components of different shapes and sizes; the precise temperature control ensures the electrical insulation performance of the product, and the low cost can meet the mass production needs of general electrical components. For high-precision electrical components (such as relays, motor windings) made of flame-retardant modified engineering plastics (PBT+GF30+flame retardant, PA66+flame retardant), the HTS PLUS series extruders are preferred. Its high mixing and dispersing effect can ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency, and meet the UL94 V-0 flame retardant standard; the precise dimensional control can ensure the dimensional accuracy of high-precision components, avoiding assembly failure. For high-end electrical components (such as high-temperature resistant connectors, aerospace electrical components) made of special engineering plastics (PPS, PSU, PES), the HTS SUPER series extruders are required. Its ultra-high torque and excellent wear resistance can cope with the high viscosity and high hardness of special engineering plastics, and the precise temperature control and short residence time can ensure the electrical insulation performance and high temperature resistance of the product, meeting the strict requirements of high-end electrical and electronic products.
4.3 Medical Field: Biocompatibility, Sterility and Precision
The medical field has extremely strict requirements on materials, and engineering plastics used in the medical field must have good biocompatibility, sterility, corrosion resistance and dimensional stability, and must not produce toxic and harmful substances. The main engineering plastics used in the medical field include PC, PA, LOER, PSU, ens., which are mainly used in medical containers, mediese kateters, mediese inplantings, surgical instruments and other products. The core requirements for extrusion processing are: hoë akkuraatheid, no pollution, stabiele prestasie, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (medical-grade PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, mediese inplantings) made of medical-grade special engineering plastics (mediese-graad PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (Good Manufacturing Practice) requirements of the medical field.
4.4 Aerospace Field: High Temperature Resistance, Low Weight and High Strength
The aerospace field has extremely high requirements on the performance of materials, and engineering plastics used in the aerospace field must have excellent high temperature resistance, low weight, high strength, corrosion resistance and radiation resistance. The main engineering plastics used in the aerospace field include PEEK, PI, PSU, PES, ens., which are mainly used in aerospace components, aircraft interior parts, satellite components and other products. The core requirements for extrusion processing are: ultra-high precision, ultra-high temperature resistance, stabiele prestasie, which require the extruder to have the highest level of torque, speed and temperature control capacity.
Due to the extremely strict processing requirements of aerospace-grade engineering plastics, only the HTS SUPER series extruders can meet the demand. Its ultra-high torque transmission device, maximum 1000rpm speed and fully optimized key components can cope with the high viscosity and high temperature resistance of aerospace-grade materials (long-term use temperature up to 300℃); the laser-clad screw and barrel have extremely high wear resistance and corrosion resistance, wat kan aanpas by die verwerking van hoë-hardheid wysigers (soos koolstofvesel, keramiekvesel); die intelligente PLC + wolk-aanraakskermbeheerstelsel kan presiese beheer van ekstrusieparameters besef, en die afstandmonitering en voorspellende instandhoudingsfunksie kan die stabiele werking van toerusting in langtermyn deurlopende produksie verseker; die aanpasbare konfigurasie kan voldoen aan die spesiale verwerkingsbehoeftes van verskeie lugvaartkomponente, om die hoë werkverrigting en hoë betroubaarheid van die produk te verseker.
4.5 Chemiese veld: Korrosieweerstand en slytasieweerstand
Die chemiese veld het 'n harde werksomgewing, en ingenieursplastiek wat in die chemiese veld gebruik word, moet uitstekende korrosiebestandheid hê, slytasie weerstand, hoë temperatuurweerstand en drukweerstand. Die belangrikste ingenieursplastiek wat in die chemiese veld gebruik word, sluit in PPS, LOER, PVDF (polyvinylidene fluoride), ens., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: weerstand teen korrosie, slytasie weerstand, stabiele prestasie, which require the extruder to have excellent wear resistance and corrosion resistance, and stable pressure control capacity.
For chemical pipelines and valves made of general corrosion-resistant engineering plastics (PPS, PVDF), the HTS PLUS series extruders are suitable. Its bimetallic composite screw and barrel have excellent corrosion resistance and wear resistance, which can adapt to the corrosion of chemical media and the wear of materials; the stable pressure control capacity can ensure the uniform wall thickness of pipelines and valves, avoiding leakage caused by uneven wall thickness. For high-pressure chemical equipment and corrosion-resistant components made of high-end corrosion-resistant engineering plastics (LOER, PI), the HTS SUPER series extruders are required. Its ultra-high torque and stable conveying capacity can cope with the high viscosity of high-end corrosion-resistant materials, and the laser-clad screw and barrel have extremely high corrosion resistance and wear resistance, which can meet the long-term use requirements in harsh chemical environments; the precise temperature control can avoid thermal decomposition of materials, ensuring the corrosion resistance and pressure resistance of the product.
5. Common Problems and Solutions in Engineering Plastics Twin-Screw Extrusion Processing
In the actual twin-screw extrusion processing of engineering plastics, due to the influence of raw materials, processing parameters, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Hieronder, we will summarize the common problems in engineering plastics extrusion processing, analyze their causes, and provide corresponding solutions combined with the characteristics of our HTS series extruders, helping enterprises solve practical processing problems and improve production efficiency.
5.1 Probleem 1: Thermal Decomposition and Discoloration of Materials
Symptoms: During the extrusion process, the material appears yellowing, blackening, carbonization and other phenomena, and the final product has discoloration, borrels, cracks and other defects, and the mechanical properties are significantly reduced. This problem is mainly caused by the sensitivity of engineering plastics to overheating and hydrolytic degradation.
Causes: 1. The extrusion temperature is too high or the temperature of a certain section of the barrel is too high, resulting in thermal decomposition of the material; 2. The residence time of the material in the extruder is too long, leading to excessive heating and decomposition; 3. The raw materials are not dried thoroughly, and the moisture in the materials causes hydrolytic degradation during high-temperature processing; 4. The screw speed is too low, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
Oplossings: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (temperature control precision ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 minute; 3. Strengthen the drying treatment of raw materials, strictly control the moisture content below 0.1%-0.2%, and use the drying device matched with the HTS series extruders to prevent the raw materials from absorbing moisture again during feeding; 4. Check and clean the die head regularly to ensure the smooth flow channel, avoid material accumulation; 5. If the problem persists, adjust the screw element combination, increase the number of conveying elements, and reduce the number of mixing elements to speed up the material conveying and shorten the residence time.
5.2 Probleem 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (soos glasvesel, koolstofvesel), and the mechanical properties (sterkte, taaiheid, slytasie weerstand) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Causes: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. The screw speed is too low, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. Die ekstrusietemperatuur is te laag, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.
Oplossings: 1. Optimize the premixing process, verhoog die mengspoed (800-1200rpm) and mixing time (5-10 minute), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, use the high-speed performance of the HTS series extruders to generate strong shear force and kneading force, and fully break the agglomerates of modifiers; 3. Adjust the combination of screw elements, increase the number of mixing elements and shearing elements, and use the modular screw design of the HTS series extruders to customize the optimal screw combination according to the type of modifier; 4. Properly increase the extrusion temperature to ensure that the material is fully melted, which is conducive to the uniform dispersion of modifiers; 5. Crush and sieve the modifier to ensure that its particle size is uniform (20-40 gaas) and meets the processing requirements.
5.3 Probleem 3: Wear of Screw and Barrel
Symptoms: After a period of use, the extrusion capacity of the extruder decreases, the shear force and mixing effect are reduced, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (soos glasvesel, koolstofvesel) on the screw and barrel during the processing of reinforced engineering plastics.
Causes: 1. Die skroef en loop is gemaak van materiale met swak slytasieweerstand, which cannot resist the wear of high-hardness modifiers; 2. The filling amount of the modifier is too high (≥50%), and the wear is intensified; 3. The particle size of the modifier is too large, which increases the wear on the screw and barrel; 4. The extrusion pressure is too high, which increases the friction between the material and the screw and barrel; 5. The screw and barrel are not maintained regularly, and the material residue accelerates the wear.
Oplossings: 1. Select extruders with high wear resistance, such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS PLUS) and ≥70 HRC (HTS SUPER), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, and apply lubricating oil appropriately to reduce friction and extend the service life. Daarby, our professional technical team can provide regular wear detection services for the screw and barrel, and put forward targeted replacement and maintenance suggestions.
5.4 Probleem 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, pype, velle) is uneven, the shrinkage rate exceeds the standard (＞1.5%), and the product has deformation, warpage and other phenomena, which affects the assembly and use of the product.
Causes: 1. The extrusion temperature is unstable, resulting in uneven melting and plasticization of the material, and uneven shrinkage during cooling; 2. The extrusion speed is unstable, leading to uneven extrusion amount and unstable product size; 3. The cooling speed is uneven, resulting in uneven internal and external stress of the product, leading to deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
Oplossings: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 minute) for strip cooling, and use air cooling or water spray cooling for pipes and sheets to avoid uneven cooling; 4. Check and optimize the die head structure, ensure the smooth flow channel, and adjust the die head temperature to ensure uniform material flow; 5. Strengthen the drying treatment of raw materials, strictly control the moisture content, and reduce the impact of moisture on product shrinkage.
5.5 Probleem 5: Low Extrusion Efficiency and High Energy Consumption
Symptoms: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
Causes: 1. The screw speed is too low, die vervoerkapasiteit is onvoldoende; 2. Die ekstrusietemperatuur is te laag, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, die vervoerkapasiteit word verminder, and the energy consumption is increased.
Oplossings: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Adjust the combination of screw elements, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, replace the worn components in time, and maintain the conveying capacity of the extruder, reducing energy consumption. Daarby, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% in vergelyking met gewone ekstrueerders.
6. Conclusion and Future Development Trend
Ingenieursplastiek, as 'n belangrike hoëprestasiemateriaal, are playing an increasingly important role in global industrial upgrading, and twin-screw extrusion technology is the core support for the high-quality processing of engineering plastics. The performance of extrusion equipment directly determines the quality, produksiedoeltreffendheid en toepassingseffek van ingenieursplastiekprodukte. Our HTS series twin-screw extruders, including HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, hoë viskositeit), with the advantages of high torque, hoë spoed, presiese temperatuurbeheer, uitstekende slytasieweerstand, wide application range and intelligent control. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, elektriese en elektroniese intelligensie, new energy and medical high-endization, the demand for high-performance, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
Eerstens, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. Terselfdertyd, digital simulation technology will be widely used in the design and debugging of extruders, reducing the research and development cycle and debugging time of equipment.
Tweedens, high performance and high efficiency. The demand for high-end engineering plastics (soos LOER, PI) will continue to increase, which will promote the continuous upgrading of extruder performance. The future extruders will have higher torque, higher speed and more precise temperature control capacity, and the key components (skroef, vat, ratkas) will be further optimized to improve wear resistance, corrosion resistance and service life. Terselfdertyd, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Derde, customization and diversification. Different application fields and different products have increasingly personalized requirements for extrusion processing. The future extruders will adopt a more flexible modular design, which can quickly replace screw elements, die heads and other components according to customer needs, realizing the processing of multiple varieties and small batches. Terselfdertyd, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Vierde, environmental protection and greenization. With the strengthening of global environmental protection policies, environmental protection will become an important development direction of extrusion equipment. The future extruders will adopt more environmentally friendly materials and manufacturing processes, reduce energy consumption and pollutant emissions; terselfdertyd, they will be more compatible with recyclable engineering plastics and biodegradable engineering plastics, promoting the green development of the engineering plastics industry.
We will always adhere to the concept of technological innovation, focus on the development needs of the engineering plastics industry, continuously invest in research and development, optimize the performance of HTS series extruders, improve after-sales service, and provide more professional, efficient and intelligent twin-screw extrusion solutions for global engineering plastics processing enterprises, helping the high-quality development of the engineering plastics industry.