Mei de rappe foarútgong fan wrâldwide yndustrialisaasje, de fraach nei materialen mei hege prestaasjes yn auto's, elektryske en elektroanyske, konstruksje, medyske en oare fjilden nimt dei ta dei ta. Engineering plastics, as in kaai hege-optreden materiaal, hawwe tradysjonele metalen materialen en algemiene plestik stadichoan ferfongen yn in protte kearnapplikaasje-senario's fanwege har treflike meganyske eigenskippen, waarmte ferset, corrosie ferset, dimensional stabiliteit en processability. Twin-screw extrusion technology is de kearn ferwurkjen technology fan engineering plestik ferbiningen, en de prestaasjes fan extrusion-apparatuer bepaalt direkt de kwaliteit, produksje effisjinsje en tapassing effekt fan engineering plestik produkten.
Wy sette ús yn foar it leverjen fan profesjonele twin-screw extrusion-oplossingen foar engineering plastic ferwurking, fertrouwe op ús ûnôfhinklik ûntwikkele en produsearre HTS-serie extruders mei gearboxen mei hege koppel, dy't spesjaal binne ûntworpen foar de ferwurkingskenmerken en tapassingsbehoeften fan technykplestik. Dit artikel sil wiidweidich útwurkje oer de prestaasjes skaaimerken, klassifikaasje, ferwurkjen swierrichheden fan engineering plestik, de kearnrol fan twin-screw extrusion technology yn engineering plastic ferwurkjen, de foardielen fan ús HTS-serie-ekstruders en har rjochte oanpassing oan engineering plestik, lykas de spesifike tapassingsfjilden, ferwurkjen techniken en mienskiplike problemen en oplossings. Troch oanfolling fan detaillearre technyske parameters, ferwurkjen details en yndustry applikaasje gefallen, it artikel sil wurde ferrike oan 3000-4000 wurden, it leverjen fan wiidweidige en profesjonele referinsje foar bedriuwen foar ferwurkjen fan yngenieurplestik, technici en relevante praktiken.
1. Oersjoch fan Engineering Plastics Industry en Core Performance Skaaimerken
1.1 Aktuele situaasje en ûntwikkeling Trend fan Engineering Plastics Industry
Engineering plestik ferwiist nei in klasse fan plestik materialen dy't kin wurde brûkt as strukturele materialen en drage meganyske lesten yn in breed temperatuer berik. Yn ferliking mei algemiene plestik (lykas polyetyleen PE, polypropylene PP, polyvinyl chloride PVC), engineering plestik hawwe mear treflike wiidweidige prestaasjes, en kin foldwaan oan de hurde gebrûk easken yn yndustriële produksje en hege-ein produkt manufacturing. Yn de lêste jierren, dreaun troch de opwurdearring fan downstream yndustry lykas automotive lichtgewicht, elektryske en elektroanyske yntelliginsje, en medyske apparaat hege-endization, de wrâldwide merk foar technykplestik hat in stabile en rappe groeitrend toand.
Neffens relevante yndustry gegevens, de grutte fan 'e wrâldwide engineering plestikmerk is grutter 100 miljard Amerikaanske dollars, en it wurdt ferwachte te behâlden in gearstalde jierlikse groei taryf fan 7%-10% yn de kommende fiif jier. Under harren, Azië-Stille Oseaan is de grutste merk foar produksje en konsumpsje fan engineeringplestik yn 'e wrâld, goed foar mear as 55% fan it wrâldwide merkoandiel, benammen troch de rappe ûntwikkeling fan automotive, elektryske en elektroanyske yndustry yn Sina, Yndia en oare lannen, likegoed as de trochgeande ferbettering fan yndustriële stypjende kapasiteit en technologyske ynnovaasje nivo. Sina, as de grutste konsumint en produsint fan engineeringplestik yn 'e wrâld, hat in grutte fraach fan 'e merk, en de jierlikse útfier en konsumpsje groeie mei in dûbelsifer taryf, benammen op it mêd fan nije enerzjyauto's, 5G kommunikaasje, en medyske apparaten, de fraach nei hege-optreden engineering plestik toant in eksplosive groei trend.
De ûntwikkelingstrend fan 'e engineering plestik yndustry wurdt benammen wjerspegele yn fiif aspekten: earste, hege prestaasjes en funksjonalisaasje. Mei de trochgeande ferbettering fan gebrûk easken yn streamôfwerts fjilden, engineering plestik ûntwikkeljen nei hegere waarmte ferset, hegere sterkte, bettere wear ferset en spesjale funksjes (lykas flammefertraging, antistatyske, antibakteriële, strieling ferset), oanpasse oan 'e hurde wurkomjouwing fan hege temperatueren, hege druk, corrosie en strieling; twadde, lichtgewicht en yntegraasje. Yn de auto, aerospace en oare fjilden, om doelen foar enerzjybesparring en útstjitreduksje te berikken, engineering plestik wurde hieltyd mear brûkt te ferfangen metalen materialen, en de yntegraasje fan produktûntwerp wurdt heger en heger, dat kin ferminderjen it oantal dielen, ferienfâldigje it produksjeproses en ferminderje kosten; tredde, miljeubeskerming en recycleberens. Mei it fersterkjen fan wrâldwide miljeubeskermingsbelied en it ferbetterjen fan bewustwêzen foar miljeubeskerming, de ûntwikkeling en tapassing fan recyclable engineering plestik, biodegradable engineering plestik en miljeufreonlike ferwurkjen technologyen binne wurden de fokus fan de yndustry, it ferminderjen fan miljeufersmoarging feroarsake troch plestik ôffal; fjirde, yntelliginsje en krektens fan ferwurkjen apparatuer. Engineering plastics hawwe hege ferwurkjen muoite en strang kwaliteit easken, dy't hegere easken stelle oan ferwurkingsapparatuer. Yntelligint, krekte en effisjinte twin-screw extruders en automatyske produksje linen wurden de mainstream fan 'e yndustry, real-time tafersjoch te realisearjen, automatyske parameter oanpassing en foarsizzend ûnderhâld fan it ferwurkjen proses; fyfde, diversifikaasje fan tapassingsfjilden. Engineering plastics wurde stadichoan útwreidzje fan tradisjonele automotive, elektryske en elektroanyske fjilden oan nije enerzjy, medysk, aerospace, bou en oare opkommende fjilden, it iepenjen fan nije merkromte.
Tsjin dizze eftergrûn, twin-screw extrusion technology, as de kearn ferwurkjen technology fan engineering plestik ferbiningen, is de kaai wurden foar it ferbetterjen fan it konkurrinsjefermogen fan technykplestikbedriuwen. Engineering plastyk is gefoelich foar oververhitting en hydrolytyske degradaasje, en hawwe hege easken oan ferwurkjen temperatuer, skuorkrêft, residinsje tiid en temperatuer kontrôle presyzje. Us HTS-serie-ekstruders binne spesjaal ûntworpen foar de ferwurkingskenmerken fan yngenieurplestik, mei hege koppel, hege snelheid, presys temperatuer kontrôle en poerbêst dispersibility, dat kin effektyf oplosse de ferwurkjen swierrichheden fan engineering plestik en helpe bedriuwen berikke hege kwaliteit, effisjinte en stabile produksje.
1.2 Core Performance Skaaimerken fan Engineering Plastics
Yn ferliking mei algemiene plestik en metalen materialen, engineering plestik hawwe unike wiidweidige prestaasjes, dy't har brede tapassing yn ferskate yndustriële fjilden bepaalt. De kearnprestaasjeskenmerken fan engineering plestik wurde benammen wjerspegele yn 'e folgjende fiif aspekten, dy't ek spesjale easken foar har ferwurkingstechnology en apparatuer foarstelle:
1.2.1 Excellent waarmte Resistance en Cold Resistance
Engineering plastics have a wide temperature adaptation range, which can maintain good mechanical properties (sterkte, hurdens, hurdens) in both high and low temperature environments. Yn ferliking mei algemiene plestik, 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℃. Tagelyk, 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 (hege temperatuer) 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. Lykwols, this also brings certain difficulties to processing: higher processing temperature is required to make them melt and plasticize, and precise temperature control is needed to avoid thermal decomposition.
1.2.2 Good Corrosion Resistance and Durability
Engineering plastics have excellent chemical stability and corrosion resistance, and are not easy to be corroded by acids, alkalis, salts, organic solvents and other chemicals. Compared with metal materials, which are easy to rust and corrode, engineering plastics have longer service life in harsh chemical environments. Bygelyks, polyamide (PA) engineering plastics are resistant to most organic solvents and weak acids and alkalis; polycarbonate (PC) engineering plestik binne resistint foar corrosie troch net-oxidizing soeren en sâlten; polyphenylene sulfide (PPS) engineering plestik binne resistint foar corrosie troch hast alle gemikaliën útsein sterke oxidizing soeren.
Derneist, engineering plastics hawwe goede waar ferset en ferâldering ferset, en binne net maklik te degradearjen en leeftyd ûnder de aksje fan sinneljocht, rein, soerstof en oare omjouwingsfaktoaren, dy't har lange termyn stabile gebrûk garandearret yn bûten- en hurde omjouwings. Dizze prestaasje makket engineering plestik in soad brûkt yn gemyske apparatuer, outdoor elektryske apparatuer, auto-eksterieurdielen en oare fjilden.
1.2.3 Maklike ferwurking en hege produksje-effisjinsje
Compared with metal materials, engineering plestik hawwe de foardielen fan maklike ferwurking, ienfâldich produksjeproses en hege produksje-effisjinsje. Metal materials usually need complex processing procedures such as forging, casting, ferwurkjen, which have high energy consumption, low efficiency and high cost; while engineering plastics can be processed by extrusion, ynjeksje moulding, blow molding and other methods, which can realize mass production, simplify the production process, reduce energy consumption and production cost. Bygelyks, the processing cycle of an engineering plastic automotive part by injection molding is only a few seconds to tens of seconds, while the processing cycle of the same metal part may take several hours to several days.
Lykwols, engineering plastics also have certain processing difficulties: they are sensitive to overheating and hydrolytic degradation, and are easy to decompose if the processing temperature is too high or the residence time is too long; tagelyk, guon engineering plestik (lykas PA) hawwe hege wetterabsorption, wat de ferwurkingseffekt en produktkwaliteit beynfloedet. Dêrom, it is needsaaklik om profesjonele ferwurkingsapparatuer en wittenskiplike ferwurkingstechniken te brûken om de ferwurkingskwaliteit te garandearjen.
1.2.4 Prachtige dimensjeel stabiliteit en elektryske isolaasje
Engineering plastics hawwe goede dimensionale stabiliteit, en de krimp is lyts (gewoanwei 0.3%-1.5%) tidens ferwurking en gebrûk, dy't de dimensionale krektens fan produkten garandearje kinne en deformaasje foarkomme. Dizze prestaasje is benammen wichtich foar dielen mei hege presyzje, lykas elektryske Anschlüsse, automotive precision komponinten, medyske apparaten, ensfh. De goede diminsjonele stabiliteit fan engineering plestik is benammen te tankjen oan har hege kristalliniteit, lege wetter absorption (útsein guon fariëteiten lykas PA) and strong intermolecular forces.
Derneist, measte engineering plestik hawwe poerbêst elektryske isolaasje prestaasjes, 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, Anschlüsse, 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). Bygelyks, 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, which can reduce fuel consumption and carbon emissions.
Tagelyk, engineering plastics also have outstanding wear resistance and friction resistance, and the friction coefficient is small, which can be used in the production of wear-resistant parts (lykas gears, lagers, sliding blocks) without additional lubrication or with less lubrication, reducing the maintenance cost of products. Bygelyks, polyoxymethylene (POM) engineering plastics have excellent wear resistance and are known as “plastic steel”, which is widely used in the production of automotive gears, electrical components and other wear-resistant parts.
1.3 Common Classification of Engineering Plastics
Engineering plastics can be divided into different types according to their chemical structure, prestaasjesnivo en tapassingsfjild. De mienskiplike klassifikaasjemetoaden binne as folget, wat helpt om de ferwurkingskenmerken en tapassingsscenario's fan ferskate technykplestik better te begripen, en selektearje passende extrusion apparatuer en ferwurkjen techniken:
1.3.1 Klassifikaasje troch Performance Level
Neffens it prestaasjesnivo, engineering plestik kin wurde ferdield yn algemien engineering plestik en spesjale engineering plestik.
- Algemiene Engineering Plastics: Se binne de meast brûkte engineering plestik, mei relatyf folwoeksen produksje technology, matige priis en goede wiidweidige prestaasjes. De wichtichste farianten binne polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), polyetyleentereftalaat (HÚSDIER), polybutylene terefthalate (PBT), ensfh. Algemiene engineering plestik wurdt benammen brûkt yn automotive, elektryske en elektroanyske, húshâldlike apparaten en oare fjilden, lykas auto-ûnderdielen, elektryske Anschlüsse, skulpen fan húshâldlike apparaten, ensfh.
- Special Engineering Plastics: Se hawwe mear treflike prestaasjes (lykas hegere waarmte ferset, corrosie ferset, meganyske eigenskippen) dan algemiene engineering plestik, mar de produksje technology is kompleks en de priis is heech. De wichtichste farianten binne polyphenylene sulfide (PPS), polyether ether keton (PEEK), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), ensfh. Spesjale engineering plestik wurdt benammen brûkt yn hege-ein fjilden lykas aerospace, medyske apparaten, nije enerzjy, en gemyske apparatuer, lykas loftfeartkomponinten, medyske ymplantaten, hege temperatuer resistint elektryske komponinten, ensfh.
1.3.2 Klassifikaasje troch gemyske struktuer
Neffens de gemyske struktuer fan 'e molekulêre keten, engineering plestik kin wurde ferdield yn polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), polyester (HÚSDIER, PBT), polyphenylene sulfide (PPS), polyether ether keton (PEEK), ensfh. Elk type engineering plestik hat syn eigen unike prestaasjes en ferwurkingseasken:
- Polyamide (PA): Ek bekend as nylon, it hat poerbêste meganyske sterkte, wear ferset, taaiens en gemyske ferset, mar hat hege wetter absorption, dy't ynfloed op de dimensionale stabiliteit. Algemiene farianten binne PA6, PA66, PA11, PA12, ensfh. It wurdt in protte brûkt yn auto-ûnderdielen (gears, lagers, intake manifolds), elektryske Anschlüsse, tekstyl fezels, ensfh.
- Polycarbonate (PC): It hat poerbêste transparânsje, impact sterkte, waarmte ferset en elektryske isolaasje, mar hat min wear ferset en is maklik te krassen. It wurdt in protte brûkt yn elektryske en elektroanyske fjilden (wiring boards, lamp covers), automotive fjilden (koplamp linzen, ynstrumint panielen), medyske fjilden (medyske konteners), ensfh.
- Polyoxymethylene (POM): It hat poerbêst wear ferset, wriuwing ferset, dimensionale stabiliteit en meganyske sterkte, en is net maklik om wetter op te nimmen. It stiet bekend as “plastic steel” en wurdt in protte brûkt yn auto-ûnderdielen (gears, sliding blocks), elektryske komponinten (switches, lagers), meganyske dielen, ensfh.
- Polyester (HÚSDIER, PBT): PET hat poerbêste transparânsje, waarmte ferset en meganyske sterkte, en wurdt benammen brûkt yn fezels, films, flessen en oare fjilden; PBT hat poerbêste gemyske ferset, elektryske isolaasje en ferwurkjen fluidity, en wurdt in soad brûkt yn elektryske en elektroanyske fjilden (Anschlüsse, relays), automotive dielen, ensfh.
- Polyphenylene Sulfide (PPS): It hat poerbêst waarmte ferset (lange-termyn gebrûk temperatuer oant 200-220 ℃), corrosie ferset, flammefertraging en elektryske isolaasje, mar hat earme taaiens. It wurdt in soad brûkt yn hege temperatuer resistinte elektryske komponinten, automotive motor dielen, gemyske apparatuer, ensfh.
- Polyether Ether Ketone (PEEK): It hat poerbêste wiidweidige prestaasjes, lange-termyn gebrûk temperatuer oant 250-300 ℃, goede corrosie ferset, meganyske sterkte en biokompatibiliteit. It wurdt fral brûkt yn hege einfjilden lykas loftfeart, medyske ymplantaten, en hege temperatuer resistint elektryske komponinten.
1.3.3 Klassifikaasje troch applikaasjefjild
Neffens it tapassingsfjild, engineering plestik kin wurde ferdield yn auto-grade engineering plestik, elektryske-grade engineering plestik, medyske-grade engineering plestik, aerospace-grade engineering plestik, ensfh. Different application fields have different requirements on the performance of engineering plastics. Bygelyks, automotive-grade engineering plastics require good heat resistance, impact strength and weather resistance; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, low weight and high strength.
2. Core Processing Technology of Engineering Plastics: Twin-Screw Extrusion Technology
Engineering plastics processing mainly includes extrusion, ynjeksje moulding, blow moulding, molding and other methods, among which twin-screw extrusion technology is the core technology for the production of engineering plastic compounds (such as modified engineering plastics, reinforced engineering plastics) and semi-finished products (lykas pipen, blêden, fezels). Yn ferliking mei single-screw extrusion technology, twin-screw extrusion technology hat de foardielen fan sterke shearing krêft, goede mingde effekt, presys temperatuer kontrôle, koarte ferbliuwstiid en sterke oanpassing oan grûnstoffen, dat kin effektyf oplosse de ferwurkjen swierrichheden fan engineering plestik (lykas gefoelichheid foar oververhitting en hydrolytyske degradaasje, min mingde effekt, lege ferwurkjen effisjinsje) en soargje foar de kwaliteit fan engineering plestik produkten.
2.1 Ferwurkjen Swierrichheden fan Engineering Plastics en easken foar extrusion Equipment
Lykas earder neamd, engineering plestik hawwe poerbêste wiidweidige prestaasjes, mar harren ferwurkjen swierrichheid is ek heger as dy fan algemiene keunststoffen, benammen troch har bysûndere molekulêre struktuer en prestaasjes skaaimerken. De wichtichste swierrichheden foar it ferwurkjen fan engineering plestik en de oerienkommende easken foar extrusion apparatuer binne as folget:
2.1.1 Gefoelichheid foar oververhitting en hydrolytyske degradaasje
De measte engineering plestik (lykas PA, PBT, PPS) binne gefoelich foar oververhitting en hydrolytyske degradaasje. As de ferwurkingstemperatuer te heech is of de ferbliuwstiid yn 'e extruder te lang is, de molekulêre keten fan it yngenieurplestik sil brekke, liedt ta termyske ûntbining, wat sil ferminderje de meganyske eigenskippen, waarmte ferset en oare prestaasjes fan it produkt, en sels ferkleuring feroarsaakje, karbonisaasje en oare defekten. Derneist, guon engineering plestik (lykas PA) hawwe hege wetterabsorption, en it focht yn it materiaal sil hydrolytyske degradaasje feroarsaakje by it ferwurkjen fan hege temperatueren, beynfloedet de produktkwaliteit.
Dit stelt twa wichtige easken foar extrusion apparatuer: earste, presys temperatuer control kapasiteit, dy't de ferwurkingstemperatuer strikt kontrolearje kin binnen it optimale berik fan engineering plestik, avoid local overheating, and the temperature control precision should reach ±1℃; twadde, koarte ferbliuwstiid, 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 (gewoanwei 1-5 minuten) en krekte temperatuerkontrôle, which are more suitable for engineering plastics processing than single-screw extruders (ferbliuwstiid 5-10 minuten).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (lykas glêstried, koalstof fiber, talk, flammefertragers, kompatibilizers) to improve the performance of the product (such as reinforcing, toughening, flamme brânfertraagjend). Bygelyks, 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. Derneist, the modular design of the twin-screw can freely combine different screw elements (lykas it oerbringen fan eleminten, mingen eleminten, shearing eleminten) 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. If the screw and barrel have poor wear resistance, they will be worn quickly, resulting in reduced shearing force and mixing capacity of the extruder, affecting the product quality and reducing the service life of the equipment.
Dit fereasket dat de skroef en de loop fan 'e extruder makke wurde fan heechweardige wearbestindige materialen en ferwurke troch avansearre produksjetechnology. Us HTS-serie-ekstruders adoptearje ymporteare slijtbestindich legere stiel foar de skroef en de loop, en ûndergean bimetallic gearstalde behanneling of laser cladding behanneling, dy't sterk ferbettert de wear ferset en corrosie ferset fan 'e skroef en barrel, en kin oanpasse oan de ferwurking fan fersterke engineering plestik mei hege hurdens modifiers.
2.1.4 Hege easken oan it ferwurkjen fan fluiditeit en drukkontrôle
Guon engineering plestik (lykas PPS, PEEK) hawwe hege viskositeit en minne ferwurkingsfluiditeit, dy't fereaskje dat de extruder sterke transportkapasiteit en drukkontrôlekapasiteit hat om de glêde fuortgong fan extrusion te garandearjen. 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; tagelyk, de extruder is foarsjoen fan in hege-precision druk 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, dy't de ynteraksje fan meardere faktoaren omfettet, lykas temperatuer, druk, skuorkrêft en tiid. 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, pipes, blêden, fezels) through the die head. It spesifike wurkprinsipe en prosesstream binne as folget:
2.2.1 Raw Material Pretreatment
Raw material pretreatment is the foundation of engineering plastics extrusion processing, which directly affects the processing effect and product quality. The raw materials of engineering plastics mainly include engineering plastic resin (lykas PA, PC, POM), modifiers (lykas glêstried, koalstof fiber, talk, flammefertragers), kompatibilizers, lubricants and other additives. De stappen foar foarbehanneling binne as folget:
- Drying behanneling: De measte engineering plestik (lykas PA, PBT, PPS) hawwe hege wetterabsorption, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, skuorren, reduced mechanical properties). Dêrom, de grûnstoffen moatte wurde droege foardat ferwurking. The drying temperature and time are determined according to the type of engineering plastic: bygelyks, PA6 is dried at 80-100℃ for 4-6 oeren, PA66 is dried at 100-120℃ for 6-8 oeren, PBT is dried at 120-140℃ for 2-4 oeren, PPS is dried at 150-160℃ for 3-5 oeren. De fochtynhâld fan 'e droege grûnstoffen moat hjirûnder kontrolearre wurde 0.1%-0.2%.
- Premixing Treatment: Neffens de formule ratio, 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. De mingsnelheid is algemien 800-1200 rpm, en it mingen tiid is 5-10 minuten. 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.
- Ferpletterjen en sieden: For engineering plastic resins with large particle size or modifiers with uneven particle size (lykas glêstried), 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. De partikelgrutte fan 'e gemalen grûnstoffen moat wurde kontrolearre op 20-40 mesh.
2.2.2 Feeding en ferfier
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. It feedapparaat fan 'e extruder is normaal foarsjoen fan in funksje foar regeljouwing fan frekwinsjekonverzje snelheid, dy't de fiedingssnelheid oanpasse kinne neffens de skroefsnelheid en extrusjesnelheid om te soargjen dat de materialen stabyl en unifoarm yn 'e extrusionholte komme, it foarkommen fan materiaalakkumulaasje of ûnfoldwaande fieding. 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, Mixing and Shearing
De materialen dy't de extrusionholte fan 'e twin-screw-extruder yngeane, wurde kontinu nei foaren skood troch de draaiende skroeven. De extrusion holte is gearstald út in skroef en in barrel, en it folume fan de extrusion holte stadichoan nimt ôf lâns de as rjochting. As de screws draaie, de materialen wurde stadichoan komprimearre ûnder de aksje fan de skroeven en de loop, en de druk yn 'e extrusion holte stadichoan nimt ta (generally 5-15MPa).
Tagelyk, de materialen wurde ûnderwurpen oan sterke skuorkrêft en wriuwingskrêft generearre troch de relative beweging tusken de skroeven en de loop, likegoed as tusken de skroef flechten. 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. De wriuwingskrêft kin ek in bepaalde hoemannichte waarmte generearje, dat wurdt kombinearre mei de eksterne ferwaarming fan it barrel (elektryske ferwaarming of stoom ferwaarming) to make the engineering plastic resin gradually melt and plasticize.
De barrel fan 'e extruder wurdt meastentiids ferdield yn 4-6 temperatuer kontrôle seksjes (feeding seksje, melting seksje, mingen seksje, homogenizing seksje, die kop seksje), and the temperature of each section is precisely controlled according to the type of engineering plastic. Bygelyks, when processing PA66+GF30 (glass fiber reinforced PA66), the temperature of the feeding section is 120-140℃, the melting section is 250-260℃, the mixing section is 260-270℃, the homogenizing section is 250-260℃, and the die head section is 240-250℃. The precise temperature control can ensure that the resin is fully melted without thermal decomposition, and the modifiers are uniformly dispersed.
2.2.4 Extrusion en foarmjouwing
De folslein smelte, mingd en ferspraat materiaal wurdt skood oan 'e die kop fan' e extruder troch de screws. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (korrels), the die head is equipped with multiple circular die holes (the number and size of die holes are determined according to the particle size of the granules); for the production of pipes, blêden, fezels, 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, pipes, blêden). De temperatuer fan 'e diekop is wat leger as dy fan' e homogenisearjende seksje, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling en Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, en de koelwettertemperatuer wurdt regele op 20-30 ℃, en de cooling tiid is 2-5 minuten; 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
Nei ôfkuolling en solidification, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (korrels), the cooled strips are sent to a granulator for cutting, and the granulator is equipped with a rotary knife, which can cut the strips into granular products with uniform size (de dieltsje grutte is algemien 2-5mm, dy't kin wurde oanpast neffens klant behoeften). 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.
Derneist, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (lykas te grut, te lyts of agglomerearre dieltsjes); the inspection step is to detect the performance (such as mechanical strength, waarmte ferset, dimensional krektens) 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, benammen ynklusyf grûnstof eigenskippen, formule ratio, premixing effekt, extrusion parameters en die kop struktuer. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.
2.3.1 Raw Materiaal Skaaimerken
It type, partikel grutte, moisture content and purity of raw materials have a great impact on the extrusion effect. Bygelyks, the particle size of engineering plastic resin and modifiers should be uniform; if the particle size is uneven, it will lead to uneven melting and mixing of materials. The moisture content of raw materials must be strictly controlled below 0.1%-0.2%; as it fochtgehalte te heech is, it will cause hydrolytic degradation of the material and bubbles in the product. De suverens fan grûnstoffen is ek tige wichtich; ûnreinheden yn grûnstoffen (such as metals, stiennen, stof) will not only affect the product quality, mar ek drage de skroef en barrel fan de extruder, en sels feroarsaakje apparatuer blokkade.
2.3.2 Formule 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. Bygelyks, tafoegjen 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. It type en de dosering fan tafoegings moatte ek ridlik oerienkomme: 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, improve processing fluidity, 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 Premixing-effekt
Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. As de premixing ûnjildich is, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, uneven mixing of materials during extrusion, and reduced product performance. Om it premix-effekt te garandearjen, it is nedich om de mingsnelheid te kontrolearjen, mingtiid en mingtemperatuer: the mixing speed is 800-1200 rpm, it mingen tiid is 5-10 minuten, en de mingtemperatuer wurdt regele op 40-60 ℃ (passende temperatuer kin ferbetterje de adhesion fan tafoegings en befoarderje unifoarm mingen).
2.3.4 Extrusion Parameters
Extrusion parameters are the most important factors affecting the extrusion effect, benammen ynklusyf screw snelheid, extrusion temperatuer en extrusion druk.
- Screw Speed: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 nei 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. Hoe heger de skroef snelheid, hoe grutter de skuorkrêft en wriuwingskrêft ûntfongen troch de materialen, the better the mixing and dispersing effect of modifiers, en hoe heger de produksje effisjinsje. Lykwols, as de skroef snelheid is te heech, de ferbliuwstiid fan de materialen yn de extrusion holte is te koart, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; as de skroef snelheid is te leech, de skuorkrêft en wriuwingskrêft binne net genôch, the modifiers cannot be fully dispersed, en de produksje effisjinsje is leech. The screw speed should be adjusted according to the type of engineering plastic and the type of modifier: for high-viscosity engineering plastics (lykas 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.
- Extrusion Temperatuer: 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. De temperatuer fan 'e feeding seksje is leger (wat heger as de droege temperatuer fan 'e grûnstoffen), dat is benammen om te foarkommen dat de materialen koekje en soargje foar glêde fieding; de temperatuer fan 'e smeltende seksje is medium, which is mainly to promote the melting and plasticization of the resin; de temperatuer fan it mingen seksje is heger, dat is benammen te ferbetterjen de skear en mingde effekt, and promote the uniform dispersion of modifiers; de temperatuer fan de homogenizing seksje is wat leger as it mingen seksje, dat is benammen om de unifoarme temperatuer en viskositeit fan 'e materialen te garandearjen, en foarkomme termyske ûntbining; de temperatuer fan de die kop seksje is wat leger as de homogenizing seksje, 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.
- Extrusion druk: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. De druk yn 'e extrusionholte wurdt benammen bepaald troch de kompresjeferhâlding fan' e skroef, de gat grutte en de skroef snelheid. Hoe heger de extrusion druk, hoe better it mingen en fersprieden effekt fan materialen, and the denser the product. Lykwols, as de druk te heech is, it sil it enerzjyferbrûk en wear fan 'e apparatuer ferheegje, en sels feroarsaakje de stjerkop te blokkearjen; as de druk te leech is, de materialen kinne net folslein komprimearre en mingd wurde, the product is loose, en de prestaasje is ynstabyl. 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, in hegere extrusion druk is nedich.
2.3.5 Die Head Struktuer
The die head structure mainly includes the shape, size and number of die holes, which directly affects the shaping effect and quality of the product. For the production of engineering plastic compounds (korrels), the die head should be equipped with multiple uniform die holes, and the size of the die holes should be matched with the particle size of the product; for the production of pipes and sheets, the die head should be designed according to the shape and size of the product, and the flow channel of the die head should be smooth to avoid material accumulation and local overheating. The die head should also be equipped with a temperature control device to ensure the uniform temperature of the die head and the stable shaping of the product.
3. Our HTS Series Extruders: Professional Solutions for Engineering Plastics Processing
Wy binne al lang dwaande mei it ûndersyk, ûntwikkeling en produksje fan hege-optreden 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, hege viskositeit) and application needs, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, perfectly adapting to the processing needs of various engineering plastics.
3.1 Core Advantages of HTS Series Extruders for Engineering Plastics Processing
3.1.1 High Torque and High Speed, Hege produksje effisjinsje
Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS series and HTS SUPER series) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, dat is folle heger as dat fan gewoane 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.
Tagelyk, 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. Derneist, the high speed design also greatly improves the production efficiency: ferlike mei gewoane extruders, 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 minuten, which is much shorter than that of ordinary twin-screw extruders (5-10 minuten) and single-screw extruders (10-15 minuten). 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.
Derneist, the screw of the HTS series extruders adopts a modular design, and different screw elements can be freely combined according to the type of engineering plastic, which can further adjust the residence time of the material, ensuring that different types of engineering plastics can obtain the optimal residence time during processing.
3.1.3 Precise temperatuerkontrôle, Stabile prestaasjes
The HTS series extruders adopt an advanced intelligent temperature control system, dy't krekte kontrôle fan 'e temperatuer fan elke seksje fan' e barrel en de diekop realisearje kin. The temperature control precision can reach ±1℃, dy't de ferwurkingstemperatuer strikt kontrolearje kin binnen it optimale berik fan engineering plestik, avoid local overheating and thermal decomposition of the material. It temperatuerkontrôlesysteem is foarsjoen fan in real-time tafersjoch- en alarmfunksje: if the temperature of any section exceeds the set range, it systeem sil op 'e tiid in alarm prompt útjaan, en sels automatysk de ferwaarmingskrêft oanpasse of de apparatuer as nedich ôfslute, om apparatuerfalen en problemen mei produktkwaliteit te foarkommen.
Derneist, 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. De diekop is ek foarsjoen fan in unôfhinklik apparaat foar temperatuerkontrôle, 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, mei in ridlike schroef pitch, lead en kompresje ratio design. It yngripen en rotearjen fan 'e twillingskroeven kin in sterke skuorkrêft en kneadkrêft generearje, which can fully break the agglomerates of modifiers (lykas glêstried, koalstof fiber, talk), make the modifiers uniformly dispersed in the engineering plastic resin matrix, and ensure the mixing and dispersing effect. The mixing uniformity of the HTS series extruders can reach more than 95%, dat is folle heger as dat fan gewoane twin-screw extruders (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (lykas it oerbringen fan eleminten, mingen eleminten, shearing eleminten) can be freely combined according to the type of engineering plastic and modifier. Bygelyks, 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 (lykas PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 Hege Wear Resistance, Lang Service Life
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 (lykas 38CrMoAlA), en ûndergean bimetallic gearstalde behanneling of laser cladding behanneling. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) en ≥70 HRC (HTS PLUS series and HTS SUPER series), dat hat ekstreem sterke wear ferset en corrosie ferset, and can effectively resist the wear caused by high-hardness modifiers. Dit gâns ferlingt de tsjinst libben fan de skroef en barrel: the service life of the screw and barrel of the HTS series extruders is 2-3 kear dat fan gewoane extruders, it ferminderjen fan de frekwinsje fan ferfanging fan komponinten en de ûnderhâldskosten fan 'e apparatuer.
Derneist, wy leverje ek tsjinsten foar profesjonele weardeteksje foar de skroef en de loop. Us technyske team sil regelmjittich de weargraad fan 'e skroef en barrel foar klanten detectearje, útjaan in detaillearre wear rapport, en foarstelle doelgerichte ferfanging en ûnderhâld suggestjes, soargje dat klanten allinich komponinten ferfange as it nedich is, it foarkommen fan ûnnedige ôffal.
3.1.6 Wide Application Range, Sterke fleksibiliteit
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, HÚSDIER, 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, ensfh.
The modular design of the HTS series extruders (skroef, barrel, die kop, ensfh.) makket it ferfangen fan komponinten handiger en flugger. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, se moatte allinnich ferfange de oerienkommende komponinten, sûnder de folsleine apparatuer te ferfangen, wat de kosten fan transformaasje fan apparatuer ferminderet en de fleksibiliteit en oanpassingsfermogen fan 'e apparatuer ferbettert. Derneist, the HTS series extruders can also be matched with different auxiliary equipment (lykas hege snelheid mixers, droegers, koelers, granulators, screening masines, packaging masines) to form a complete automatic production line, it realisearjen fan trochgeande produksje fan foarbehanneling fan grûnstoffen oant produktferpakking.
3.1.7 Intelligent Control, Maklike operaasje en ûnderhâld
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, dat is ienfâldich en yntuïtyf, maklik te betsjinjen. It systeem kin meardere sets produktformules en ferwurkingsparameters opslaan. When customers produce different types of engineering plastics, se hoege allinich de oerienkommende formule en parameters te neamen, sûnder werhelle debuggen, dat besparret tiid en ferbettert produksje effisjinsje.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (lykas temperatuer, druk, screw snelheid, feeding speed) 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, dy't kinne realisearje remote parameter oanpassing, produksje gegevens tafersjoch en foarsizzend ûnderhâld fan apparatuer, it realisearjen fan yntelliginte produksjebehear.
Derneist, the HTS series extruders adopt a reasonable structural design, dat makket it ûnderhâld handiger. De skroef, barrel, die holle en oare ûnderdielen kinne wurde útinoar en gearstald fluch, dat ferleget de ûnderhâld tiid en arbeid yntinsiteit. Us tsjinst nei-ferkeap team sil soargje profesjonele ynstallaasje, commissioning en training tsjinsten foar klanten, soargje dat klanten de apparatuer soepel kinne brûke.
3.2 HTS Series Extruder Produkttypen en harren oanpassing oan Engineering Plastics
Om te foldwaan oan 'e ferskate ferwurkingsbehoeften fan technykplestikbedriuwen fan ferskate skalen en produkttypen, wy hawwe lansearre trije wichtichste produkt types yn de HTS rige: HTS BASIC series, HTS PLUS series and HTS SUPER series. Elke searje hat syn eigen skaaimerken en rjochte oanpassingssenario's, dat kin wurde selektearre troch klanten neffens harren eigen produksje skaal, produkt type, budzjet en oare faktoaren.
3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. Dizze searje extruders brûkt gearboxen mei medium koppel fan liedende Jeropeeske fabrikanten, dy't de foardielen hawwe fan stabile prestaasjes, leech lûd, hege effisjinsje en lange libbensdoer. The medium-torque design (specific torque 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, HÚSDIER, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
Yn termen fan struktureel ûntwerp, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, mei in skroef diameter fariearjend fan 30mm oant 65mm, en in kompresjeferhâlding fan 4-8, which can be adjusted according to the type of engineering plastic. De barrel is makke fan wearbestindich legere stiel mei nitridingbehandeling, en de skroef is makke fan wear-resistant en corrosie-resistant alloy stiel, dat hat goede wear ferset. De extruder is foarsjoen fan in PLC kontrôle systeem en in touch skerm operaasje ynterface, dat kin realisearje automatyske feeding, automatyske temperatuer kontrôle, automatyske druk kontrôle en automatyske cutting, en is ienfâldich en maklik te betsjinjen.
De produksjekapasiteit fan 'e HTS BASIC-serie extruders farieart fan 100kg / h oant 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. Ien fan 'e grutste foardielen fan dizze rige is dat it kin biede fleksibele opsjes fia ferskate konfiguraasje kombinaasjes. Klanten kinne kieze ferskate skroef eleminten, de koppen, feeding apparaten, droechapparaten en neiferwurkingsapparatuer neffens har eigen produkttypen, produksje kapasiteit en budzjet, om in produksjeline te foarmjen dy't geskikt is foar har eigen behoeften. De HTS BASIC-serie extruders hawwe in ridlike priis, dy't bedriuwen kinne helpe om de inisjele ynvestearringskosten te ferminderjen.
3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastics and Modified Products
De extruders fan 'e HTS PLUS-searje nimme gearboxen mei hege koppel oan ûnôfhinklik ûntwikkele en produsearre troch ús, 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 (lykas PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
De extruders fan 'e HTS PLUS-searje hawwe in skroefdiameter fariearjend fan 65 mm oant 110 mm, in kompresjeferhâlding fan 5-10, and a screw speed range of 200～800 rpm. De skroef en barrel nimme bimetallyske gearstalde behanneling oan, dat hat hegere wear ferset en corrosie ferset (oerflak hurdens ≥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 (lykas PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics
De extruders fan 'e HTS SUPER-searje adoptearje it lêste oerdrachtapparaat mei ultra-hege koppel ûnôfhinklik ûntwikkele troch ús, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Doel fan it hege koppel en hege snelheid skaaimerken fan dizze rige, it strukturele ûntwerp fan elke kaaikomponint fan 'e extruder is folslein optimalisearre, dat is ús heechste-ein extruder rige, fertsjintwurdiget it avansearre nivo fan Sina syn extruder ûntwikkeling. 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, hege prestaasjes en yntelliginsje.
The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, in kompresjeferhâlding fan 6-12, and a screw speed range of 250～1000 rpm. De skroef en barrel nimme ymportearre wear-resistant alloy stiel en laser cladding technology, dat hat ekstreem hege wear ferset en corrosie ferset (surface hardness ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. De extruder is foarsjoen fan in yntelliginte PLC + wolk touch skerm kontrôle systeem, dy't kinne realisearje remote parameter oanpassing, production data monitoring, predictive maintenance of equipment and data analysis, it realisearjen fan yntelliginte produksjebehear.
De produksjekapasiteit fan 'e HTS SUPER-serie extruders farieart fan 1000kg / h oant 3000kg / h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. Dizze searje extruders hat de foardielen fan hege presyzje, sterke maatwurk, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minuten) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Derneist, 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, bedriuwen moatte har eigen produksjebehoeften wiidweidich beskôgje, produkt types, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. De folgjende binne wat spesifike seleksje suggestjes:
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, HÚSDIER, 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 (filling bedrach 30%-50%, such as glass fiber reinforced PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (lykas 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. Foar lytsskalige produksje (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; for large-scale production (1000kg/h – 3000kg/h), such as large-scale production of high-end special engineering plastics or large orders from downstream enterprises, the HTS SUPER series with screw diameter of 80mm – 130mm is the best choice. It should be noted that when selecting, enterprises should not blindly pursue large production capacity. They should also consider the fluctuation of order quantity. If the order quantity is unstable, they can choose equipment with adjustable speed and flexible production capacity (such as HTS BASIC series with frequency conversion speed regulation function) to avoid waste of equipment resources and energy.
3.3.3 Consider the Modification Demand and Mixing Effect
If the enterprise’s main products are modified engineering plastics, the mixing and dispersing effect of the extruder is the key factor to be considered. For products that need to add a variety of modifiers (such as flame retardants, kompatibilizers, reinforcing agents) tagelyk, it is necessary to select extruders with excellent mixing performance, such as HTS PLUS series and HTS SUPER series with modular mixing screw elements. These two series can freely combine conveying elements, mixing elements and shearing elements according to the type of modifier, adjust the mixing intensity and residence time, and ensure that various modifiers are uniformly dispersed in the resin matrix. Bygelyks, when processing flame-retardant modified PBT, more mixing elements can be configured to ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. Derneist, 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. Derneist, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, ynklusyf ynstallaasje, commissioning, technyske training, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.
3.3.5 Consider the Compatibility with Auxiliary Equipment
Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, high-speed mixer, cooler, granulator, screening machine, packaging machine, ensfh. 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. Bygelyks, 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
Engineering plastics, with their excellent comprehensive performance, have been widely used in automotive, elektryske en elektroanyske, medysk, aerospace, gemysk, 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. Ûnder, 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: Lichtgewicht, 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, ensfh., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: lichtgewicht, high temperature resistance, wear ferset, dimensional stability and low VOC (flechtige organyske ferbiningen), 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, doar panielen, lucht kanalen) 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.
Case Study: 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 minuten) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% nei 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Elektryske isolaasje, 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, wiring boards, relays, motors, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, flammefertraging, dimensional stabiliteit, corrosion resistance and low toxicity, which require the extruder to have precise temperature control, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, Anschlüsse) 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, ensfh., which are mainly used in medical containers, medyske katheters, medyske ymplantaten, surgical instruments and other products. The core requirements for extrusion processing are: hege presyzje, no pollution, stabile prestaasjes, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (medical-grade PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, medyske ymplantaten) made of medical-grade special engineering plastics (medyske-graad PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (Goede Manufacturing Practice) requirements of the medical field.
4.4 Aerospace Field: High Temperature Resistance, Low Weight and High Strength
The aerospace field has extremely high requirements on the performance of materials, and engineering plastics used in the aerospace field must have excellent high temperature resistance, low weight, high strength, corrosion resistance and radiation resistance. The main engineering plastics used in the aerospace field include PEEK, PI, PSU, PES, ensfh., 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, stabile prestaasjes, 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, wear ferset, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), ensfh., which are mainly used in chemical equipment, pipelines, kleppen, pumps and other products. The core requirements for extrusion processing are: corrosie ferset, wear ferset, stabile prestaasjes, 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, due to the influence of raw materials, ferwurkjen parameters, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Ûnder, we will summarize the common problems in engineering plastics extrusion processing, analyze their causes, and provide corresponding solutions combined with the characteristics of our HTS series extruders, helping enterprises solve practical processing problems and improve production efficiency.
5.1 Problem 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, bubbels, cracks and other defects, and the mechanical properties are significantly reduced. This problem is mainly caused by the sensitivity of engineering plastics to overheating and hydrolytic degradation.
Causes: 1. The extrusion temperature is too high or the temperature of a certain section of the barrel is too high, resulting in thermal decomposition of the material; 2. The residence time of the material in the extruder is too long, leading to excessive heating and decomposition; 3. The raw materials are not dried thoroughly, and the moisture in the materials causes hydrolytic degradation during high-temperature processing; 4. The screw speed is too low, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
Solutions: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (temperature control precision ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 minuten; 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 Problem 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (lykas glêstried, koalstof fiber), and the mechanical properties (sterkte, hurdens, wear ferset) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Causes: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. The screw speed is too low, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, 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.
Solutions: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 minuten), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, use the high-speed performance of the HTS series extruders to generate strong shear force and kneading force, and fully break the agglomerates of modifiers; 3. Adjust the combination of screw elements, increase the number of mixing elements and shearing elements, and use the modular screw design of the HTS series extruders to customize the optimal screw combination according to the type of modifier; 4. Properly increase the extrusion temperature to ensure that the material is fully melted, which is conducive to the uniform dispersion of modifiers; 5. Crush and sieve the modifier to ensure that its particle size is uniform (20-40 mesh) and meets the processing requirements.
5.3 Problem 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 (lykas glêstried, koalstof fiber) on the screw and barrel during the processing of reinforced engineering plastics.
Causes: 1. The screw and barrel are made of materials with poor wear resistance, 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.
Solutions: 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) en ≥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. Derneist, our professional technical team can provide regular wear detection services for the screw and barrel, en foarstelle doelgerichte ferfanging en ûnderhâld suggestjes.
5.4 Problem 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, pipes, blêden) is uneven, the shrinkage rate exceeds the standard (＞1.5%), and the product has deformation, warpage and other phenomena, which affects the assembly and use of the product.
Causes: 1. The extrusion temperature is unstable, resulting in uneven melting and plasticization of the material, and uneven shrinkage during cooling; 2. The extrusion speed is unstable, leading to uneven extrusion amount and unstable product size; 3. The cooling speed is uneven, resulting in uneven internal and external stress of the product, leading to deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
Solutions: 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 minuten) 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 Problem 5: Low Extrusion Efficiency and High Energy Consumption
Symptoms: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
Causes: 1. The screw speed is too low, the conveying capacity is insufficient; 2. The extrusion temperature is too low, 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, the conveying capacity is reduced, and the energy consumption is increased.
Solutions: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Adjust the combination of screw elements, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, replace the worn components in time, and maintain the conveying capacity of the extruder, reducing energy consumption. Derneist, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% ferlike mei gewoane extruders.
6. Conclusion and Future Development Trend
Engineering plastics, as in kaai hege-optreden materiaal, 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, produksje effisjinsje en tapassing effekt fan engineering plestik produkten. Our HTS series twin-screw extruders, including HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, hege viskositeit), with the advantages of high torque, hege snelheid, presys temperatuer kontrôle, poerbêst wear ferset, wide application range and intelligent control. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, elektryske en elektroanyske yntelliginsje, new energy and medical high-endization, the demand for high-performance, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
Earste, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. Tagelyk, 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.
Twadde, 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 (skroef, barrel, gearbox) will be further optimized to improve wear resistance, corrosion resistance and service life. Tagelyk, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Tredde, 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. Tagelyk, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Fjirde, 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; tagelyk, 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.