Cù u rapidu avanzu di l'industrializazione glubale, a dumanda di materiali d'alta prestazione in l'automobile, elettricu è elettronicu, custruzzione, i campi medichi è altri cresce ogni ghjornu. Plastica ingegneria, cum'è un materiale chjave d'alta prestazione, anu rimpiazzatu gradualmente i materiali metallichi tradiziunali è i plastichi generali in parechji scenarii di applicazioni core per via di e so eccellenti proprietà meccaniche, resistenza à u calore, resistenza à a corrosione, stabilità dimensionale è processability. A tecnulugia di estrusione à doppia vite hè a tecnulugia di trasfurmazioni core di cumposti plastichi di ingegneria, è u funziunamentu di l'equipaggiu di estrusione determina direttamente a qualità, efficienza di pruduzzione è effettu di l'applicazione di i prudutti di plastica di l'ingegneria.
Ci impegnimu à furnisce soluzioni prufessiunali di estrusione à doppia vite per a trasfurmazioni di plastica ingegneria, cunfidendu nantu à i nostri estrusori di a serie HTS sviluppati è fabbricati in modu indipendenti cù scatole di ingranaggi di alta coppia, chì sò apposta per e caratteristiche di trasfurmazioni è i bisogni di l'applicazione di i plastichi di l'ingegneria. Questu articulu hà da elaburà in modu cumpletu nantu à e caratteristiche di u rendiment, classificazione, difficultà di trasfurmazioni di plastica ingegneria, u rolu core di a tecnulugia di estrusione à doppia vite in a trasfurmazioni di plastica ingegneria, i vantaghji di i nostri estrusori di a serie HTS è a so adattazione mirata à i plastichi di l'ingegneria, è ancu i campi d'applicazione specifichi, tecnichi di trasfurmazioni è prublemi cumuni è suluzione. Per cumplementà i paràmetri tecnichi detallati, dettagli di trasfurmazioni è casi di applicazioni di l'industria, l'articulu sarà arricchitu à 3000-4000 parolle, furnisce riferimentu cumpletu è prufessiunale per l'imprese di trasfurmazioni di plastica ingegneria, tecnichi è pratichi pertinenti.
1. Panoramica di l'industria di l'ingegneria plastica è e caratteristiche di u rendimentu core
1.1 Situazione attuale è Tendenza di Sviluppu di l'Industria Plastica Ingegneria
I plastichi di l'ingegneria si riferiscenu à una classe di materiali plastichi chì ponu esse aduprati cum'è materiali strutturali è portanu carichi meccanichi in una larga gamma di temperatura.. Comparatu cù plastichi generale (cum'è polietilene PE, polipropilene PP, PVC di cloruru di polivinile), i plastichi di l'ingegneria anu un rendimentu cumpletu più eccellente, è pò scuntrà i bisogni di usu duru in a pruduzzione industriale è a fabricazione di prudutti high-end. In l'ultimi anni, guidatu da l'aghjurnamentu di l'industrii downstream cum'è l'automobile ligera, intelligenza elettrica è ilittronica, è high-endization dispusitivu medicale, u mercatu glubale di plastica ingegneria hà dimustratu una tendenza di crescita stabile è rapida.
Sicondu i dati pertinenti di l'industria, a dimensione di u mercatu globale di plastica ingegneria hà superatu 100 miliardi di dollari americani, è hè previstu di mantene una crescita annuale composta di 7%-10% in i prossimi cinque anni. À mezu à elli, L'Asia-Pacificu hè u più grande mercatu di pruduzzioni è cunsumu di plastica ingegneria in u mondu, cuntabili per più di 55% di a quota di mercatu globale, soprattuttu per via di u rapidu sviluppu di l'automobile, industrie elettriche è elettroniche in Cina, India è altri paesi, in quantu à a migliione cuntinua di a capacità di sustegnu industriale è u livellu di l'innuvazione tecnologica. Cina, cum'è u più grande cunsumadore è pruduttore di plastica ingegneria in u mondu, hà una grande dumanda di u mercatu, è a pruduzzione annuale è u cunsumu crescenu à un ritmu di duie cifre, in particulare in i campi di i veiculi d'energia nova, 5G cumunicazioni, è dispusitivi medichi, a dumanda di plastica ingegneria high-performance mostra una tendenza di crescita splusivi.
A tendenza di sviluppu di l'industria di l'ingegneria plastica hè principalmente riflessa in cinque aspetti: primu, altu rendiment è funziunalità. Cù u migliuramentu cuntinuu di e esigenze di usu in i campi downstream, plastica ingegneria sò sviluppatu versu a resistenza à u calore più altu, forza più altu, megliu resistenza à l'usura è funzioni speciale (cum'è a ritardanza di fiamma, antistaticu, antibacterial, resistenza à a radiazione), per adattà à l'ambiente di travagliu duru di alta temperatura, alta pressione, corrosione è radiazione; sicondu, liggeru è integrazione. In l'automobile, aerospaziale è altri campi, per ottene ugettivi di risparmiu energeticu è di riduzione di emissioni, i plastichi di l'ingegneria sò sempre più usati per rimpiazzà i materiali metallici, è l'integrazione di u disignu di u produttu hè sempre più altu, chì pò riduce u numeru di parti, simplificà u prucessu di produzzione è riduce i costi; terzu, prutezzione di l'ambiente è riciclabilità. Cù u rinfurzamentu di e pulitiche di prutezzione di l'ambiente globale è a migliione di a cuscenza di a prutezzione ambientale, u sviluppu è l'applicazione di plastica ingegneria riciclabile, i plastichi biodegradabili di l'ingegneria è e tecnulugia di trasfurmazioni amichevuli di l'ambiente sò diventati u focu di l'industria, riducendu a contaminazione ambientale causata da i rifiuti plastichi; quartu, intelligenza è precisione di l'equipaggiu di trasfurmazioni. I plastichi di l'ingegneria anu una alta difficultà di trasfurmazioni è esigenze strette di qualità, chì ponenu esigenze più altu nantu à l'equipaggiu di trasfurmazioni. Intelligente, L'extruders twin-screw precisi è efficaci è e linee di produzzione automatiche sò diventate u mainstream di l'industria, realizà un monitoraghju in tempu reale, l'ajustamentu automaticu di i paràmetri è u mantenimentu predittivu di u prucessu di trasfurmazioni; quintu, diversificazione di i campi di applicazione. I plastichi di l'ingegneria si sviluppanu gradualmente da l'automobile tradiziunale, campi elettrici è elettronichi à a nova energia, medicale, aerospaziale, custruzzione è altri campi emergenti, aprendu un novu spaziu di mercatu.
Contra stu sfondate, tecnulugia di estrusione à doppia vite, cum'è a tecnulugia di trasfurmazioni core di cumposti plastichi di ingegneria, hè diventatu a chjave per migliurà a cumpetitività di l'imprese di plastica ingegneria. I plastichi di l'ingegneria sò sensibili à u surriscaldamentu è a degradazione idrolitica, è avè esigenze elevate nantu à a temperatura di trasfurmazioni, forza di taglio, tempu di residenza è precisione di cuntrollu di temperatura. I nostri estrusori di a serie HTS sò apposta per e caratteristiche di trasfurmazioni di plastica ingegneria, cù un altu torque, alta velocità, precise temperature control and excellent dispersibility, which can effectively solve the processing difficulties of engineering plastics and help enterprises achieve high-quality, efficient and stable production.
1.2 Core Performance Characteristics of Engineering Plastics
Compared with general plastics and metal materials, engineering plastics have unique comprehensive performance, which determines their wide application in various industrial fields. The core performance characteristics of engineering plastics are mainly reflected in the following five aspects, which also put forward special requirements for their processing technology and equipment:
1.2.1 Excellent Heat Resistance and Cold Resistance
Engineering plastics have a wide temperature adaptation range, which can maintain good mechanical properties (forza, durezza, durezza) in both high and low temperature environments. Comparatu cù plastichi generale, which usually lose their mechanical properties at 80-120℃, most engineering plastics can work stably at 100-250℃, and some special engineering plastics (such as PEEK, PI) can even work at temperatures above 300℃. In listessu tempu, engineering plastics also have good cold resistance, which can maintain good toughness at low temperatures (below -40℃), and are not easy to brittle fracture. This performance makes engineering plastics suitable for use in harsh temperature environments, such as automotive engine parts (alta temperatura) and outdoor electrical equipment (low temperature).
The excellent heat resistance of engineering plastics is mainly due to their special molecular structure (such as aromatic rings, heterocyclic rings) and strong intermolecular forces, which makes them not easy to melt and decompose at high temperatures. Tuttavia, chistu porta dinù certi difficultà à trasfurmazioni: temperatura di trasfurmazioni più altu hè necessariu per fà li funnu è plasticize, è un cuntrollu di temperatura precisa hè necessariu per evità a descomposizione termica.
1.2.2 Bona resistenza à a corrosione è durabilità
I plastichi di l'ingegneria anu una stabilità chimica eccellente è resistenza à a corrosione, è ùn sò micca faciuli per esse corroded da l'acidi, alcalis, sali, solventi organici è altri chimichi. Comparatu cù i materiali metallici, chì sò faciuli à arruggini è corrode, i plastichi di l'ingegneria anu una vita di serviziu più longa in ambienti chimichi duri. Per esempiu, poliamide (PA) plastica ingegneria sò resistenti à a maiò parte di i solventi organici è l'acidi debuli è l'alkali; policarbonate (PC) plastica ingegneria sò resistenti à a corrosione da acidi non-oxidizing è sali; sulfuru di polifenilene (PPS) plastica ingegneria sò risistenti à currusioni da quasi tutti i sustanzi chimichi eccettu acidi oxidizing forti.
In più, i plastichi di l'ingegneria anu una bona resistenza à u clima è a resistenza à l'anziane, è ùn sò micca fàciule di degradà è invechjate sottu l'azzione di u sole, piova, ossigenu è altri fatturi ambientali, chì assicura u so usu stabile à longu andà in ambienti esterni è duri. Questa prestazione rende a plastica ingegneria largamente usata in l'equipaggiu chimicu, equipaghji elettrici esterni, parti esterni di l'automobile è altri campi.
1.2.3 Trattamentu faciule è alta efficienza di produzzione
Comparatu cù i materiali metallici, plastica ingegneria hannu i vantaghji di trasfurmazioni faciuli, prucessu di pruduzzione simplice è alta efficienza di produzzione. I materiali metallici sò generalmente bisognu di prucedure cumplesse di trasfurmazioni cum'è a forgiatura, casting, machining, chì anu un altu cunsumu d'energia, bassa efficienza è altu costu; mentre chì i plastichi di l'ingegneria ponu esse trasfurmati per estrusione, stampaggio a iniezione, colpu molding è altri metudi, chì pò realizà a pruduzzioni di massa, simplificà u prucessu di pruduzzioni, riduce u cunsumu energeticu è u costu di produzzione. Per esempiu, u ciculu di trasfurmazioni di una parte di l'automobilistica plastica di l'ingegneria per stampà à iniezione hè solu da pochi seconde à decine di seconde, mentri u ciclu di trasfurmazioni di a stessa parte metallica pò piglià parechje ore à parechji ghjorni.
Tuttavia, plastica ingegneria dinù hannu certi difficultà trasfurmazioni: sò sensibili à u surriscaldamentu è a degradazione idrolitica, è sò faciuli à decompose si a temperatura di trasfurmazioni hè troppu altu o u tempu di residenza hè troppu longu; in listessu tempu, qualchi plastica ingegneria (cum'è PA) avè un altu assorbimentu d'acqua, chì afecta l'effettu di trasfurmazioni è a qualità di u produttu. Dunque, it is necessary to use professional processing equipment and scientific processing techniques to ensure the processing quality.
1.2.4 Excellent Dimensional Stability and Electrical Insulation
Engineering plastics have good dimensional stability, and the shrinkage rate is small (di solitu 0.3%-1.5%) during processing and use, which can ensure the dimensional accuracy of products and avoid deformation. This performance is particularly important for high-precision parts, such as electrical connectors, automotive precision components, dispusitivi medichi, ecc. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) and strong intermolecular forces.
In più, most engineering plastics have excellent electrical insulation performance, which can maintain good insulation performance in a wide temperature range and frequency range, and are not easy to conduct electricity and arc. This makes engineering plastics widely used in electrical and electronic fields, such as wiring boards, cable ties, connettori, relays, motors and other electrical components.
1.2.5 Light Weight and High Specific Strength, Outstanding Wear Resistance
Engineering plastics have the characteristics of light weight (density is 1/3-1/5 of metal materials) and high specific strength (strength per unit weight is equivalent to or even higher than that of metal materials). Per esempiu, the specific strength of glass fiber reinforced polyamide (PA66+GF30) is higher than that of ordinary carbon steel, which can effectively reduce the weight of products while ensuring the mechanical performance. This performance is particularly important in the automotive, aerospace and other fields that pursue lightweight and energy saving, chì ponu riduce u cunsumu di carburante è l'emissioni di carbone.
In listessu tempu, plastica ingegneria dinù hannu una resistenza eccezziunale usura è resistenza attritu, è u coefficient di attritu hè chjucu, chì pò esse usatu in a pruduzzioni di parti resistenti à l'usura (cum'è ingranaggi, cuscinetti, blocchi scorrevule) senza lubricazione supplementu o cù menu lubrificante, riducendu u costu di mantenimentu di i prudutti. Per esempiu, poliossimetilene (POM) plastica ingegneria hannu una resistenza eccellente usura è sò cunnisciuti cum'è “azzaru plasticu”, chì hè largamente utilizatu in a produzzione di ingranaggi di l'automobile, cumpunenti elettrici è altre parti resistenti à l'usura.
1.3 Classificazione cumuna di Plastics Engineering
Plastica ingegneria pò esse divisu in diversi tipi secondu a so struttura chimica, livellu di prestazione è campu di applicazione. I metudi di classificazione cumuni sò i seguenti, chì aiuta à capisce megliu e caratteristiche di trasfurmazioni è i scenarii d'applicazione di diverse plastiche ingegneria, è selezziunate l'equipaggiu di estrusione adattatu è e tecniche di trasfurmazioni:
1.3.1 Classificazione per Livellu di Prestazione
Sicondu u livellu di rendiment, plastica ingegneria pò esse divisu in plastica ingegneria generale è plastica ingegneria spiciali.
- General Engineering Plastics: Sò i plastichi di l'ingegneria più utilizati, cù tecnulugia di pruduzzione relativamente matura, prezzu moderatu è bona prestazione cumpleta. I variità principali include poliamide (PA), policarbonate (PC), poliossimetilene (POM), polietilene tereftalato (PET), polibutilene tereftalato (PBT), ecc. I plastichi di l'ingegneria generale sò principalmente usati in l'automobile, elettricu è elettronicu, l'apparecchi di casa è altri campi, cum'è e parti di l'automobile, connettori elettrici, cunchiglia di l'apparecchi di casa, ecc.
- Plastica Ingegneria Speciale: Hanu un rendimentu più eccellente (cum'è una resistenza à u calore più altu, resistenza à a corrosione, proprietà meccaniche) cà i plastichi di l'ingegneria generale, ma a tecnulugia di pruduzzione hè cumplessa è u prezzu hè altu. I variità principali include sulfuru di polifenilene (PPS), polietherether chetone (PEEK), poliimide (PI), polisulfone (PSU), polietersulfone (PES), ecc. I plastichi speciali di l'ingegneria sò principalmente usati in campi high-end cum'è aerospaziale, dispusitivi medichi, energia nova, è l'equipaggiu chimicu, cum'è cumpunenti aerospaziale, implanti medichi, cumpunenti elettrici resistenti à alta temperatura, ecc.
1.3.2 Classificazione per struttura chimica
Sicondu a struttura chimica di a catena molekulari, plastica ingegneria pò esse divisu in polyamide (PA), policarbonate (PC), poliossimetilene (POM), poliester (PET, PBT), sulfuru di polifenilene (PPS), polietherether chetone (PEEK), ecc. Ogni tipu di plastica ingegneria hà e so caratteristiche uniche di prestazione è esigenze di trasfurmazioni:
- Poliamide (PA): Hè cunnisciutu ancu nylon, hà una forza meccanica eccellente, resistenza à l'usura, tenacità è resistenza chimica, ma hà una alta absorption d'acqua, chì afecta a stabilità dimensionale. I variità cumuni includenu PA6, PA66, PA11, PA12, ecc. Hè largamente utilizatu in parti di l'automobile (ingranaggi, cuscinetti, manifolds di aspirazione), connettori elettrici, fibre tessili, ecc.
- Policarbonate (PC): Hà una trasparenza eccellente, forza di impattu, resistenza à u calore è insulazione elettrica, ma hà una scarsa resistenza à l'usura è hè faciule da scratch. Hè largamente utilizatu in i campi elettrici è elettronichi (schede di cablaggio, coperchi di lampade), campi di l'automobile (lenti di fari, pannelli di strumenti), campi medichi (cuntenituri medichi), ecc.
- Poliossimetilene (POM): Havi una eccellente resistenza à l'usura, resistenza à l'attrito, stabilità dimensionale è forza meccanica, è ùn hè micca faciule d'assorbà l'acqua. Hè cunnisciutu cum'è “azzaru plasticu” è hè largamente utilizatu in parti di l'automobile (ingranaggi, blocchi scorrevule), cumpunenti elettrici (interruttori, cuscinetti), parti meccaniche, ecc.
- Poliester (PET, PBT): PET hà una trasparenza eccellente, resistenza à u calore è forza meccanica, è hè principalmente usatu in fibres, filmi, bottiglie è altri campi; PBT hà una resistenza chimica eccellente, insulazione elettrica è fluidità di trasfurmazioni, è hè largamente utilizatu in i campi elettrici è elettronichi (connettori, relays), parti di l'automobile, ecc.
- sulfuru di polifenilene (PPS): Havi una excelente resistenza à u calore (a temperatura di usu à longu andà finu à 200-220 ℃), resistenza à a corrosione, ritardante di fiamma è insulazione elettrica, ma hà una scarsa durezza. Hè largamente utilizatu in cumpunenti elettrici resistenti à alta temperatura, parti di u mutore di l'automobile, equipamentu chimicu, ecc.
- Polyether Ether Ketone (PEEK): Havi un rendimentu cumpletu eccellente, temperatura d'usu longu finu à 250-300 ℃, bona resistenza à a corrosione, forza meccanica è biocompatibilità. Hè principarmenti usatu in campi high-end cum'è aerospaziale, implanti medichi, è cumpunenti elettrici resistenti à alta temperatura.
1.3.3 Classificazione per Campu di Applicazione
Sicondu u campu di l'applicazione, plastica ingegneria pò esse divisu in plastica ingegneria di qualità automobilistica, plastica ingegneria di qualità elettrica, plastica ingegneria di qualità medica, plastiche ingegneria aerospaziale, ecc. Diversi campi di applicazione anu esigenze diverse nantu à a prestazione di plastica ingegneria. Per esempiu, i plastichi di l'ingegneria di l'automobile necessitanu una bona resistenza à u calore, forza d'impattu è resistenza à u clima; I plastichi di l'ingegneria di qualità elettrica necessitanu un bonu insulamentu elettricu è un ritardante di fiamma; i plastichi di l'ingegneria di qualità medica necessitanu una bona biocompatibilità è sterilità; i plastichi ingegneria aerospaziale necessitanu una bona resistenza à alta temperatura, pocu pesu è alta forza.
2. Tecnulugia di Trattamentu di Core di Plastica Ingegneria: Tecnulugia di estrusione à doppia vite
U prucessu di plastica ingegneria include principalmente l'estrusione, stampaggio a iniezione, soffiatura, molding è altri metudi, trà i quali a tecnulugia di estrusione di twin-screw hè a tecnulugia di core per a produzzione di cumposti plastichi di l'ingegneria (cum'è plastiche ingegneria mudificate, plastica ingegneria rinfurzata) è i prudutti semifiniti (comu pipi, fogli, fibres). In cunfrontu cù a tecnulugia di estrusione di una sola vite, A tecnulugia di estrusione à doppia vite hà i vantaghji di una forte forza di taglio, bonu effettu di mischju, cuntrollu precisu di a temperatura, cortu tempu di residenza è forte adattabilità à a materia prima, chì ponu risolve efficacemente e difficultà di trasfurmazioni di plastica ingegneria (cum'è a sensibilità à u surriscaldamentu è a degradazione idrolitica, effettu di mischju poviru, bassa efficienza di trasfurmazioni) è assicurà a qualità di i prudutti di plastica ingegneria.
2.1 Difficultà di Trattamentu di Plastica Ingegneria è Requisiti per l'equipaggiu di estrusione
Comu diciatu prima, i plastichi di l'ingegneria anu un eccellente rendimentu cumpletu, ma a so difficultà di trasfurmazioni hè ancu più altu ch'è quellu di plastica generale, principarmenti per via di a so struttura molekulari particulare è e caratteristiche di prestazione. I principali difficultà di trasfurmazioni di plastica ingegneria è i requisiti currispondenti per l'equipaggiu di estrusione sò i seguenti:
2.1.1 Sensibilità à u surriscaldamentu è a degradazione idrolitica
A maiò parte di plastica ingegneria (cum'è PA, PBT, PPS) sò sensibili à u surriscaldamentu è a degradazione idrolitica. Se a temperatura di trasfurmazioni hè troppu alta o u tempu di residenza in l'extruder hè troppu longu, 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. In più, qualchi plastica ingegneria (cum'è PA) avè un altu assorbimentu d'acqua, 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: primu, 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℃; sicondu, tempu di residenza brevi, 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 (di solitu 1-5 minuti) è un cuntrollu precisu di a temperatura, which are more suitable for engineering plastics processing than single-screw extruders (tempu di residenza 5-10 minuti).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, fibra di carbone, talcu, ritardanti di fiamma, cumpatibili) to improve the performance of the product (such as reinforcing, toughening, ritardante di fiamma). Per esempiu, 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. In più, the modular design of the twin-screw can freely combine different screw elements (cum'è elementi di trasportu, mischjà elementi, elementi di taglio) 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 the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), the added glass fiber, carbon fiber and other modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder during the extrusion process. Se a vite è a canna anu poca resistenza à l'usura, seranu purtati prestu, resulting in reduced shearing force and mixing capacity of the extruder, affecting the product quality and reducing the service life of the equipment.
Questu hè bisognu chì a vite è a canna di l'estrusore deve esse fatta di materiali resistenti à l'usura di alta qualità è trattatu da tecnulugia di fabricazione avanzata.. Our HTS series extruders adopt imported wear-resistant alloy steel for the screw and barrel, è sottumessi à un trattamentu compostu bimetallicu o trattamentu di cladding laser, 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, PEEK) 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; in listessu tempu, 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, chì implica l'interazzione di parechji fatturi cum'è a temperatura, pressione, forza di taglio è tempu. 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, pipi, fogli, fibres) through the die head. U principiu di travagliu specificu è u flussu di prucessu sò i seguenti:
2.2.1 Pretrattamentu di materia prima
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 (cum'è PA, PC, POM), modifiers (such as glass fiber, fibra di carbone, talcu, ritardanti di fiamma), cumpatibili, lubricants and other additives. I passi di pretrattamentu sò i seguenti:
- Trattamentu di secca: A maiò parte di plastica ingegneria (cum'è PA, PBT, PPS) avè un altu assorbimentu d'acqua, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, crepe, reduced mechanical properties). Dunque, a materia prima deve esse secca prima di trasfurmà. The drying temperature and time are determined according to the type of engineering plastic: per esempiu, PA6 is dried at 80-100℃ for 4-6 ore, PA66 is dried at 100-120℃ for 6-8 ore, PBT is dried at 120-140℃ for 2-4 ore, PPS is dried at 150-160℃ for 3-5 ore. U cuntenutu di umidità di a materia prima secca deve esse cuntrullata quì sottu 0.1%-0.2%.
- Premixing Treatment: Sicondu a ratio di formula, 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. A velocità di mischju hè in generale 800-1200 rpm, è u tempu di mischju hè 5-10 minuti. 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.
- Frantumazione e vagliatura: For engineering plastic resins with large particle size or modifiers with uneven particle size (such as glass fiber), 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. A dimensione di particella di a materia prima triturata deve esse cuntrullata à 20-40 maglia.
2.2.2 Alimentazione è trasportu
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. U dispusitivu di alimentazione di l'extruder hè di solitu dotatu di una funzione di regulazione di velocità di cunversione di frequenza, chì pò aghjustà a velocità di alimentazione secondu a vitezza di a vite è a velocità di estrusione per assicurà chì i materiali entranu in a cavità di estrusione in modu stabile è uniforme., evitendu l'accumulazione di materiale o l'alimentazione insufficiente. The feeding hopper is also equipped with a drying device to prevent the raw materials from absorbing moisture again during feeding.
2.2.3 Melting, Miscelazione è tosatura
I materiali chì entranu in a cavità di estrusione di l'estrusore à doppia vite sò spinti in avanti continuamente da i viti rotanti.. A cavità di estrusione hè cumpostu da una viti è un canna, è u voluminu di a cavità di estrusione diminuisce gradualmente longu a direzzione di l'assi. Quandu i viti giranu, i materiali sò gradualmente cumpressi sottu à l'azzione di i viti è di u canna, è a prissioni in a cavità di estrusione aumenta gradualmente (generally 5-15MPa).
In listessu tempu, i materiali sò sottumessi à una forte forza di taglio è forza di attritu generata da u muvimentu relativo trà i viti è u canna, è ancu trà i voli di viti. 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. A forza di attritu pò ancu generà una certa quantità di calore, chì hè cumminatu cù u riscaldamentu esternu di u canna (riscaldamentu elettricu o riscaldamentu à vapore) to make the engineering plastic resin gradually melt and plasticize.
U canna di l'extruder hè di solitu divisu in 4-6 sezioni di cuntrollu di temperatura (sezione di alimentazione, sezione di fusione, sezione di mischju, sezione omogeneizzante, sezione testa die), and the temperature of each section is precisely controlled according to the type of engineering plastic. Per esempiu, 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 Estrusione è Shaping
U cumpletamente fusu, u materiale mistu è spargugliatu hè imbuttatu à a testa di l'extruder da i viti. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (granuli), 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, fogli, fibres, 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, pipi, fogli). A tampiratura di a testa di morta hè ligeramente più bassa di quella di a seccione homogenizing, 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 Raffreddamentu è solidificazione
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℃, è u tempu di rinfrescante hè 2-5 minuti; 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
Dopu à rinfriscà è solidificazione, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (granuli), 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 (a dimensione di particella hè generalmente 2-5mm, chì pò esse aghjustatu secondu i bisogni di u cliente). 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.
In più, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (cum'è troppu grande, particelle troppu chjuche o agglomerate); the inspection step is to detect the performance (such as mechanical strength, resistenza à u calore, precisione dimensionale) 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, include principalmente e caratteristiche di a materia prima, ratio di formula, effettu premixing, i paràmetri di estrusione è a struttura di a testa. 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 Caratteristiche di a materia prima
U tipu, dimensione di particella, moisture content and purity of raw materials have a great impact on the extrusion effect. Per esempiu, 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%; se u cuntenutu di umidità hè troppu altu, it will cause hydrolytic degradation of the material and bubbles in the product. A purità di a materia prima hè ancu assai impurtante; impurità in materie prime (such as metals, petre, polvara) will not only affect the product quality, ma ancu purtate a vite è a canna di l'extruder, è ancu pruvucà u bloccu di l'equipaggiu.
2.3.2 Formula ratio
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. Per esempiu, aghjunghjendu 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. U tipu è a dosa di l'additivi ancu deve esse ragiunate cumminatu: 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, migliurà a fluidità di trasfurmazioni, 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 Effettu di premixing
Premixing hè u fundamentu di u prucessu di estrusione. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. Se u premixing hè irregulare, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, mistura irregolare di materiali durante l'estrusione, and reduced product performance. Per assicurà l'effettu premixing, hè necessariu di cuntrullà a velocità di mischju, u tempu di mischju è a temperatura di mischju: the mixing speed is 800-1200 rpm, u tempu di mischju hè 5-10 minuti, è a temperatura di mischju hè cuntrullata à 40-60 ℃ (temperatura adatta pò migliurà l'aderenza di additivi è prumove un mischju uniforme).
2.3.4 Parametri di estrusione
I paràmetri di estrusione sò i fatturi più impurtanti chì afectanu l'effettu di estrusione, principarmenti cumpresi vitezza vite, temperatura di estrusione è pressione di estrusione.
- Velocità di Vite: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 à 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. A più alta hè a vitezza di a vite, più grande hè a forza di taglio è a forza di attritu ricevutu da i materiali, the better the mixing and dispersing effect of modifiers, è u più altu l'efficienza di pruduzzione. Tuttavia, se a vitezza di a vite hè troppu alta, u tempu di residenza di i materiali in a cavità di estrusione hè troppu cortu, resulting in incomplete melting of the resin, mistura insufficiente di materiali, and uneven product quality; se a vitezza di a vite hè troppu bassu, a forza di taglio è a forza di attritu sò insufficienti, the modifiers cannot be fully dispersed, è l'efficienza di a produzzione hè bassa. 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, PEEK), a lower screw speed is needed to ensure sufficient melting and mixing; for reinforced engineering plastics (such as glass fiber reinforced PA), a higher screw speed is needed to ensure the uniform dispersion of glass fiber.
- Temperature di estrusione: 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. A temperatura di a seccione di alimentazione hè più bassu (ligeramente più altu ch'è a temperatura di secca di e materie prime), chì hè principalmente per prevene i materiali da caking è assicurà l'alimentazione liscia; a temperatura di a seccione di fusione hè mediu, which is mainly to promote the melting and plasticization of the resin; a temperatura di a seccione di mischju hè più altu, chì hè principalmente per rinfurzà l'effettu di cisura è mischju, and promote the uniform dispersion of modifiers; a temperatura di a rùbbrica homogenizing hè ligeramente più bassu chè a rùbbrica mischjera, chì hè principalmente per assicurà a temperatura uniforme è a viscosità di i materiali, è evite a descomposizione termica; a temperatura di a rùbbrica di testa die hè un pocu più bassu chè a rùbbrica homogenizing, 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.
- Pressione di estrusione: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. A pressione in a cavità di estrusione hè principalmente determinata da u rapportu di compressione di a vite, a dimensione di u foru è a velocità di a vite. A più alta hè a pressione di estrusione, u megliu l'effettu di mischjà è disperse di i materiali, and the denser the product. Tuttavia, se a pressione hè troppu alta, aumenterà u cunsumu d'energia è l'usura di l'equipaggiu, è ancu pruvucà a testa di morsa per bluccà; se a pressione hè troppu bassu, i materiali ùn ponu micca esse cumpressi è mischiati, the product is loose, è u rendiment hè inestabile. 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, una pressione di estrusione più altu hè necessariu.
2.3.5 Struttura di a testa
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 (granuli), 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
Avemu longu esse impegnati in a ricerca, 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, alta viscosità) 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, Alta efficienza di produzzione
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 (Serie HTS PLUS è serie HTS SUPER) 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.
In listessu tempu, 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. In più, the high speed design also greatly improves the production efficiency: paragunatu cù extruders ordinariu, 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 minuti, which is much shorter than that of ordinary twin-screw extruders (5-10 minuti) and single-screw extruders (10-15 minuti). 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.
In più, 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 Cuntrolu di a temperatura precisa, 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, u sistema emetterà un prompt di alarme in tempu, and even automatically adjust the heating power or shut down the equipment if necessary, per evità fallimentu di l'equipaggiu è prublemi di qualità di u produttu.
In più, 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. A testa di die hè ancu dotata di un dispositivu indipendenti di cuntrollu di temperatura, 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, cù un passu di vite raghjone, cuncepimentu di piombo è rapportu di compressione. L'intermeshing è a rotazione di i viti gemelli ponu generà una forte forza di taglio è forza di impastamentu, which can fully break the agglomerates of modifiers (such as glass fiber, fibra di carbone, talcu), 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 (cum'è elementi di trasportu, mischjà elementi, elementi di taglio) can be freely combined according to the type of engineering plastic and modifier. Per esempiu, 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 Alta resistenza à l'usura, Longa vita di serviziu
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced 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 (cum'è 38CrMoAlA), è sottumessi à un trattamentu compostu bimetallicu o trattamentu di cladding laser. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) è ≥70 HRC (Serie HTS PLUS è serie HTS SUPER), chì hà una resistenza à l'usura estremamente forte è a resistenza à a corrosione, and can effectively resist the wear caused by high-hardness modifiers. Questu estende assai a vita di serviziu di u vitu è u canna: the service life of the screw and barrel of the HTS series extruders is 2-3 volte quella di extruders ordinariu, riducendu a frequenza di rimpiazzamentu di cumpunenti è u costu di mantenimentu di l'equipaggiu.
In più, furnimu ancu servizii di rilevazione di usu prufessiunale per a vite è a canna. U nostru squadra tecnicu rilevarà regularmente u gradu di usura di a vite è di a canna per i clienti, emette un rapportu detallatu di usura, è presenta suggerimenti di sostituzione è mantenimentu mirati, assicurendu chì i clienti rimpiazzà solu cumpunenti quandu necessariu, evitendu i rifiuti inutili.
3.1.6 Ampia gamma di applicazioni, 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, PEEK, 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, ecc.
The modular design of the HTS series extruders (vite, canna, more testa, ecc.) makes the replacement of components more convenient and quick. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, they only need to replace the corresponding components, without replacing the entire equipment, chì riduce u costu di trasfurmazioni di l'equipaggiu è migliurà a flessibilità è l'adattabilità di l'equipaggiu. In più, the HTS series extruders can also be matched with different auxiliary equipment (cum'è i miscelatori d'alta velocità, asciugatrici, coolers, granulatori, macchine di screening, macchine imballaggio) to form a complete automatic production line, realizà a pruduzzione cuntinuu da u pretrattamentu di a materia prima à l'imballu di u produttu.
3.1.7 Intelligent Control, Funzionamentu è Mantenimentu faciule
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, chì hè simplice è intuitive, faciuli à upirari. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, solu bisognu di chjamà a formula è i paràmetri currispondenti, senza debugging ripetutu, which saves time and improves production efficiency.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (cum'è a temperatura, pressione, vitezza vite, velocità di alimentazione) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, realizing intelligent production management.
In più, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. The screw, canna, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. A nostra squadra di serviziu dopu a vendita furnisce una installazione prufessiunale, servizii di cumissioni è furmazione per i clienti, assicurendu chì i clienti ponu aduprà l'equipaggiu senza problemi.
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, Serie HTS PLUS è serie HTS SUPER. 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 Estrusore serie HTS BASIC: 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. Questa serie di estrusori utilizza scatole di ingranaggi di coppia media da i principali fabricatori europei, chì anu i vantaghji di un rendiment stabile, bassu rumore, alta efficienza è longa vita di serviziu. The medium-torque design (coppia specifica 10-12 Nm/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 quantu à u disignu strutturale, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, cù un diametru di vite chì varieghja da 30 mm à 65 mm, è un rapportu di compressione di 4 ~ 8, which can be adjusted according to the type of engineering plastic. A canna hè fatta d'acciaio in lega resistente à l'usura cù trattamentu di nitrurazione, è a vite hè fatta di azzaru di lega resistente à l'usura è a corrosione, chì hà una bona resistenza à l'usura. L'estrusore hè dotatu di un sistema di cuntrollu PLC è di una interfaccia d'operazione di schermu tattile, which can realize automatic feeding, cuntrollu automaticu di a temperatura, cuntrollu di pressione autumàticu è taglio autumàticu, 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. One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, moriri capi, dispusitivi di alimentazione, drying devices and post-processing equipment according to their own product types, capacità di pruduzzione è u budgetu, in modu di furmà una linea di produzzione adattata per i so bisogni. The HTS BASIC series extruders have a reasonable price, chì ponu aiutà l'imprese à riduce u costu d'investimentu iniziale.
3.2.2 Estrusore serie HTS PLUS: High-Performance Choice for Engineering Plastics and Modified Products
The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, 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%, carbon fiber reinforced 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 Estrusore serie HTS SUPER: Top-End Choice for High-End Engineering Plastics
L'estrusori di a serie HTS SUPER adoptanu l'ultimu dispositivu di trasmissione di torque ultra-altu sviluppatu indipendentemente da noi, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Scopre à u torque altu è e caratteristiche di alta velocità di sta serie, u disignu strutturale di ogni cumpunente chjave di l'extruder hè stata cumplettamente ottimizzata, chì hè a nostra serie di extruder high-end, rapprisentanu u livellu avanzatu di sviluppu extruder di China. This series of extruders is mainly designed for the processing of high-end special engineering plastics (such as PEEK, 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, high performance and intelligence.
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, which has extremely high wear resistance and corrosion resistance (durezza di a superficia ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. The extruder is equipped with an intelligent PLC + cloud touch screen control system, which can realize remote parameter adjustment, production data monitoring, predictive maintenance of equipment and data analysis, realizing intelligent production management.
The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minuti) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. In più, 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, l'imprese anu bisognu di cunsiderà in modu cumpletu i so bisogni di produzzione, tippi di prudutti, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. Eccu alcuni suggerimenti di selezzione specifichi:
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 (quantità di riempimentu 30%-50%, such as glass fiber reinforced 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 (PEEK, 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. Per a pruduzzione à piccula scala (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; per a pruduzzione à grande scala (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 Cunsiderate a dumanda di mudificazione è l'effettu di mischju
Sì i prudutti principali di l'impresa sò plastichi di ingegneria mudificati, l'effettu di mischju è dispersing di l'extruder hè u fattore chjave per esse cunsideratu. Per i prudutti chì anu bisognu di aghjunghje una varietà di modificatori (cum'è i ritardanti di fiamma, cumpatibili, agenti di rinfurzà) in listessu tempu, hè necessariu di selezziunà extruders cù un rendimentu di mischju eccellente, cum'è a serie HTS PLUS è a serie HTS SUPER cù elementi di viti di mistura modulari. Queste duie serie ponu cumminà liberamente elementi di trasportu, elementi mischjà è elementi shearing secondu u tipu di mudificatore, aghjustate l'intensità di mischju è u tempu di residenza, è assicuratevi chì diversi modificatori sò uniformi dispersi in a matrice di resina. Per esempiu, quandu si tratta di PBT mudificatu ignifugo, 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. In più, 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. In più, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, inclusa a stallazione, cumissioni, furmazione tecnica, 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, mixer à alta velocità, cooler, granulator, screening machine, packaging machine, ecc. 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. Per esempiu, 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
Plastica ingegneria, with their excellent comprehensive performance, have been widely used in automotive, elettricu è elettronicu, medicale, aerospaziale, chimicu, 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. Sottu, 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: Ligeru, 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, ecc., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: ligeru, high temperature resistance, resistenza à l'usura, dimensional stability and low VOC (composti organici volatili), 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, pannelli di porte, i canali d'aria) 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 (PEEK, 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.
Studiu di casu: 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 minuti) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. Dopu avè usatu l'estrusori di a serie HTS SUPER, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% à 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Isolamentu Elettricu, 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, schede di cablaggio, relays, mutori, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, ritardante di fiamma, stabilità dimensionale, 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, connettori) 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, PEEK, PSU, ecc., which are mainly used in medical containers, cateteri medichi, implanti medichi, surgical instruments and other products. The core requirements for extrusion processing are: alta precisione, no pollution, prestazione stabile, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (cum'è cuntenituri medichi, ordinary catheters) made of medical-grade general engineering plastics (PC di qualità medica, 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, implanti medichi) made of medical-grade special engineering plastics (PEEK di qualità medica, 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 (A bona pratica di fabricazione) 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, ecc., 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, prestazione stabile, 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, which can adapt to the processing of high-hardness modifiers (such as carbon fiber, ceramic fiber); the intelligent PLC + cloud touch screen control system can realize precise control of extrusion parameters, and the remote monitoring and predictive maintenance function can ensure the stable operation of equipment in long-term continuous production; the customizable configuration can meet the special processing needs of various aerospace components, ensuring the high performance and high reliability of the product.
4.5 Chemical Field: Corrosion Resistance and Wear Resistance
The chemical field has harsh working environment, and engineering plastics used in the chemical field must have excellent corrosion resistance, resistenza à l'usura, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), ecc., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: resistenza à a corrosione, resistenza à l'usura, prestazione stabile, 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 (PEEK, 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, per via di l'influenza di a materia prima, paràmetri di prucessu, equipment performance and other factors, sò spessu parechji prublemi, which affect the product quality and production efficiency. Sottu, we will summarize the common problems in engineering plastics extrusion processing, analizà e so cause, 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 Prublemu 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, bolle, 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.
Cause: 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. A vitezza di a vite hè troppu bassu, 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.
Soluzioni: 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 (precisione di cuntrollu di temperatura ± 1 ℃) to avoid local overheating; 2. Aumente a vitezza di a vite in modu adattatu (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 minuti; 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 Prublemu 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (such as glass fiber, fibra di carbone), and the mechanical properties (forza, durezza, resistenza à l'usura) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Cause: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. A vitezza di a vite hè troppu bassu, 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. A temperatura di extrusion hè troppu bassu, 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.
Soluzioni: 1. Optimize the premixing process, aumentà a velocità di mischju (800-1200rpm) and mixing time (5-10 minuti), 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. Aumente a vitezza di a vite in modu adattatu, 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 maglia) and meets the processing requirements.
5.3 Prublemu 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 (such as glass fiber, fibra di carbone) on the screw and barrel during the processing of reinforced engineering plastics.
Cause: 1. U vitu è u canna sò fatti di materiali cù poca resistenza à l'usura, 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.
Soluzioni: 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) è ≥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. In più, our professional technical team can provide regular wear detection services for the screw and barrel, è presenta suggerimenti di sostituzione è mantenimentu mirati.
5.4 Prublemu 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, pipi, fogli) 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.
Cause: 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.
Soluzioni: 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 minuti) 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 Prublemu 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.
Cause: 1. A vitezza di a vite hè troppu bassu, a capacità di trasportu hè insufficiente; 2. A temperatura di extrusion hè troppu bassu, 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, a capacità di trasportu hè ridutta, and the energy consumption is increased.
Soluzioni: 1. Aumente a vitezza di a vite in modu adattatu (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. In più, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% paragunatu cù extruders ordinariu.
6. Conclusion and Future Development Trend
Plastica ingegneria, cum'è un materiale chjave d'alta prestazione, 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, efficienza di pruduzzione è effettu di l'applicazione di i prudutti di plastica di l'ingegneria. Our HTS series twin-screw extruders, cumpresu 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, alta viscosità), with the advantages of high torque, alta velocità, cuntrollu precisu di a temperatura, eccellente resistenza à l'usura, 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, cù l'aghjurnamentu cuntinuu di l'industrii downstream cum'è l'automobile ligera, intelligenza elettrica è ilittronica, nova energia è high-endization medicale, a dumanda di altu rendiment, plastiche di ingegneria funziunali è ecologiche continueranu à cresce, chì ancu mette in avanti esigenze più elevate nantu à a tecnulugia è l'equipaggiu di estrusione à doppia vite. A tendenza di u sviluppu futuru di l'estrusori à doppia vite di plastica ingegneria serà principalmente riflessa in quattru aspetti.:
Primu, intelligenza è digitalizazione. Cù u sviluppu di l'industria 4.0, L'extruders twin-screw seranu più integrati cù tecnulugia intelligenti cum'è Internet di e Cose, big data è intelligenza artificiale. L'estrusori di a serie HTS ottimizzeranu ancu più a funzione di cuntrollu di nuvola, realizà un monitoraghju in tempu reale, analisi di dati, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. In listessu tempu, 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.
Sicondu, high performance and high efficiency. The demand for high-end engineering plastics (such as PEEK, 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 (vite, canna, gearbox) will be further optimized to improve wear resistance, corrosion resistance and service life. In listessu tempu, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Terzu, 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. In listessu tempu, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Quartu, 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; in listessu tempu, 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.