Bi pêşveçûna bilez a pîşesaziya gerdûnî, daxwaza materyalên bi performansa bilind di otomotîvê de, elektrîk û elektronîk, avahî, bijîjkî û warên din roj bi roj zêde dibin. Endezyariya plastîk, wekî materyalek sereke ya performansa bilind, ji ber taybetmendiyên wan ên mekanîkî yên hêja di gelek senaryoyên serîlêdana bingehîn de hêdî hêdî şûna materyalên metal ên kevneşopî û plastîkên gelemperî girtine., berxwedana germê, berxwedana korozyonê, îstîqrara dimensî û pêvajoyiyê. Teknolojiya derxistina du-pişk teknolojiya pêvajoyek bingehîn a pêkhateyên plastîk ên endezyariyê ye, û performansa alavên derxistinê rasterast kalîteyê diyar dike, karîgeriya hilberînê û bandora serîlêdana hilberên plastîk ên endezyariyê.
Em pêbawer in ku ji bo hilberandina plastîkên endezyariyê çareseriyên derxistina du-pişkên profesyonel peyda bikin, xwe dispêre extruderên rêze HTS yên serbixwe yên pêşkeftî û çêkirî yên bi gearboksên bilind-torque, ku bi taybetî ji bo taybetmendiyên pêvajoyê û hewcedariyên serîlêdanê yên plastîkên endezyariyê hatine çêkirin. Ev gotar dê bi berfirehî li ser taybetmendiyên performansê berfireh bike, bisinifkirinî, zehmetiyên pêvajoyê yên plastîkên endezyariyê, rola bingehîn a teknolojiya derxistina du-pişkan di hilberandina plastîkên endezyariyê de, avantajên extruderên me yên rêze HTS û adaptasyona wan a armanckirî ji plastîkên endezyariyê re, û her weha qadên serîlêdanê yên taybetî, teknîkên pêvajoyê û pirsgirêk û çareseriyên hevpar. Bi lêzêdekirina pîvanên teknîkî yên berfireh, hûrguliyên pêvajoyê û dozên serîlêdana pîşesaziyê, gotar dê were dewlemend kirin 3000-4000 peyvên, ji bo pargîdaniyên hilberîna plastîk ên endezyariyê referansa berfireh û profesyonel peyda dike, teknîsyen û pisporên têkildar.
1. Berfirehiya Pîşesaziya Plastîka Endezyariyê û Taybetmendiyên Performansa Nû
1.1 Rewşa heyî û Trendiya Pêşveçûna Endezyariya Pîşesaziya Plastîkê
Plastîkên endezyariyê çînek materyalên plastîk vedibêjin ku dikarin wekî materyalên avahîsaziyê werin bikar anîn û di navgînek germahiya berfireh de barên mekanîkî hilgirin.. Li gorî plastîkên gelemperî (wek polyethylene PE, polypropylene PP, polyvinyl chloride PVC), plastîkên endezyariyê xwedan performansa berbiçav a berbiçav e, û dikare di hilberîna pîşesazî û hilberîna hilberê ya bilind-end de hewcedariyên karanîna dijwar bicîh bîne. Di salên dawî de, ji hêla nûvekirina pîşesaziyên jêrîn ên wekî sivikahiya otomotîvê ve hatî rêve kirin, îstîxbarata elektrîkê û elektronîk, û cîhaza bijîjkî ya bilind-dawîbûnê, bazara plastîkên endezyariya gerdûnî meylek mezinbûna domdar û bilez nîşan daye.
Li gorî daneyên pîşesaziyê yên têkildar, mezinahiya bazara plastîkên endezyariya gerdûnî derbas bûye 100 milyar dolarên Amerîkî, û tê pêşbînîkirin ku rêjeyek mezinbûna salane ya tevlihev biparêze 7%-10% di pênc salên pêş de. Di nav wan de, Asya-Pasîfîk mezintirîn bazara hilberîn û vexwarina plastîkên endezyariyê ya cîhanê ye, hesab ji bo zêdetir ji 55% ji pişka bazara cîhanî, bi taybetî ji ber pêşveçûna bilez a otomotîvê, pîşesaziya elektrîkê û elektronîk li Çînê, Hindistan û welatên din, û her weha başkirina domdar a kapasîteya piştevaniya pîşesaziyê û asta nûjeniya teknolojîk. çîn, wekî mezintirîn xerîdar û hilberînerê plastîkên endezyariyê yên cîhanê, daxwazek mezin a bazarê heye, û hilber û vexwarina salane bi rêjeyek dujimarî mezin dibe, bi taybetî di warên wesayîtên enerjiya nû de, 5G ragihandinê, û amûrên tibbî, daxwaza ji bo plastîkên endezyariya bi performansa bilind meylek mezinbûna teqîner nîşan dide.
Meyla pêşkeftina pîşesaziya plastîk a endezyariyê bi giranî di pênc aliyan de tê xuyang kirin: yekem, performansa bilind û fonksiyonelbûnê. Bi pêşveçûna domdar a daxwazên karanîna li qadên jêrîn, plastîkên endezyariyê berbi berxwedana germahiya bilindtir pêşve diçin, hêza bilind, berxwedana wear baştir û fonksiyonên taybet (wek paşxistina agir, antîstatîk, antîbakteriyal, berxwedana tîrêjê), ku bi hawîrdora xebata dijwar a germahiya bilind re adapte bibin, tansiyona bilind, korozyon û radyasyonê; duyem, sivik û entegrasyonê. Di otomotîvê de, asmanî û qadên din, ji bo bidestxistina armancên teserûfa enerjiyê û kêmkirina emîsyonê, plastîkên endezyariyê ji bo şûna materyalên metal zêde têne bikar anîn, û yekbûna sêwirana hilberê bilind û bilindtir dibe, ku dikare hejmara beşan kêm bike, pêvajoya hilberînê hêsan bike û lêçûn kêm bike; sêyem, parastina jîngehê û vezîvirandinê. Bi xurtkirina polîtîkayên parastina jîngehê yên gerdûnî û başkirina hişmendiya parastina jîngehê, pêşveçûn û serîlêdana plastîkên endezyariya vezîvirandinê, plastîkên endezyariyê yên biyolojîk û teknolojiyên pêvajoyek dostaniya jîngehê bûne navenda pîşesaziyê, kêmkirina qirêjiya jîngehê ya ku ji ber bermahiyên plastîk pêk tê; çarem, îstîxbarat û rastbûna alavên pêvajoyê. Plastîkên endezyariyê xwedan zehmetiya pêvajoyek bilind û daxwazên kalîteyê yên hişk in, ku daxwazên bilindtir li ser alavên pêvajoyê derdixe pêş. Reweşenbîr, extruderên du-pişk û xetên hilberîna otomatîkî yên rast û bikêrhatî bûne sereke ya pîşesaziyê, pêkanîna çavdêriya dema rast, verastkirina parametreya otomatîkî û domandina pêşbînîkirî ya pêvajoya pêvajoyê; pêncem, cihêrengkirina qadên serîlêdanê. Plastîkên endezyariyê hêdî hêdî ji otomotîla kevneşopî berfireh dibin, zeviyên elektrîkê û elektronîkî ji bo enerjiya nû, pizişkî, asmanî, avahî û qadên din ên nûjen, vekirina cîhê bazarê nû.
Li hemberî vê paşerojê, teknolojiya extrusion du-screw, wekî teknolojiya bingehîn a hilberandina pêkhateyên plastîk ên endezyariyê, bûye mifteya başkirina pêşbaziya pargîdaniyên plastîk ên endezyariyê. Plastîkên endezyariyê ji germbûna zêde û hilweşîna hîdrolîtîk hesas in, û li ser germahiya pêvajoyê hewcedariyên bilind hene, hêza rijandinê, dema rûniştinê û rastbûna kontrolkirina germahiyê. Extruderên me yên rêza HTS bi taybetî ji bo taybetmendiyên pêvajoyê yên plastîkên endezyariyê hatine çêkirin, bi torque bilind, leza bilind, kontrolkirina germahiya rastîn û belavbûna hêja, ku dikare bi bandor zehmetiyên pêvajoyê yên plastîkên endezyariyê çareser bike û ji pargîdaniyan re bibe alîkar ku bigihîjin kalîteya bilind, hilberîna bikêr û bi îstîqrar.
1.2 Taybetmendiyên Performansa bingehîn ên Plastîkên Endezyariyê
Li gorî materyalên plastîk û metal ên gelemperî, plastîkên endezyariyê xwedan performansa berfireh a bêhempa ye, ku serîlêdana wan a berfireh di warên cûrbecûr pîşesaziyê de diyar dike. Taybetmendiyên performansa bingehîn ên plastîkên endezyariyê bi giranî di pênc aliyên jêrîn de têne xuyang kirin, ku di heman demê de ji bo teknolojî û alavên wan ên hilberandinê jî daxwazên taybetî derdixe pêş:
1.2.1 Berxwedana Germê û Berxwedana Sermayê ya Berbiçav
Plastîkên endezyarî xwedan rêzek adaptasyona germahiyê ya berfireh e, ku dikare taybetmendiyên mekanîkî yên baş biparêze (qawet, dijwarî, serhişkî) hem di hawîrdorên germahiya bilind û hem jî yên nizm de. Li gorî plastîkên gelemperî, ku bi gelemperî di 80-120℃ de taybetmendiyên xwe yên mekanîkî winda dikin, piraniya plastîkên endezyariyê dikarin li 100-250℃ bi îstîqrar bixebitin, û hin plastîkên endezyariya taybetî (wek PEEK, PI) dikare di germahiyên ji 300℃ de jî bixebite. Vê bigire, plastîkên endezyariyê jî xwedan berxwedana sar a baş e, ku dikare di germên nizm de hişkbûna baş biparêze (jêr -40 ℃), û ji bo şikestinan ne hêsan in. Ev performans plastîkên endezyariyê ji bo karanîna di hawîrdorên germahiya dijwar de maqûl dike, wek parçeyên motora otomobîlan (germahiya bilind) û alavên elektrîkê li derve (germahiya nizm).
Berxwedana germê ya hêja ya plastîkên endezyariyê bi piranî ji ber avahiya wan a molekularî ya taybetî ye (wek zengilên bîhnxweş, zengilên heterocyclic) û hêzên intermolecular xurt, ku dihêle ku ew di germahiyên bilind de ne hêsan werin helandin û hilweşandin. Lebê, ev jî ji bo pêvajoyê hin zehmetiyan tîne: Germahiya hilberandinê ya bilindtir hewce ye ku ew bihelin û plastîk bibin, û kontrolkirina germê ya rastîn hewce ye ku ji hilweşîna termal dûr nekevin.
1.2.2 Berxwedana Korozyonê û Dûrbûna baş
Plastîkên endezyariyê xwedan aramiya kîmyewî û berxwedana korozyonê ya hêja ye, û ne hêsan e ku ji hêla asîdan ve werin xera kirin, alkalis, xwê, solavên organîk û kîmyewî yên din. Li gorî materyalên metal, yên ku bi hêsanî rizandin û xera dibin, plastîkên endezyariyê di hawîrdorên kîmyewî yên dijwar de jiyana karûbarê dirêjtir in. Bo nimûne, polyamide (PA) plastîkên endezyariyê li hember piraniya helawerên organîk û asîdên qels û alkalan berxwedêr in; polycarbonate (PC) plastîkên endezyariyê li hember korozyonê ji hêla asîd û xwêyên ne-oksîdker ve berxwedêr in; polyphenylene sulfide (PPS) engineering plastics are resistant to corrosion by almost all chemicals except strong oxidizing acids.
Herwisa, engineering plastics have good weather resistance and aging resistance, and are not easy to degrade and age under the action of sunlight, rain, oxygen and other environmental factors, which ensures their long-term stable use in outdoor and harsh environments. This performance makes engineering plastics widely used in chemical equipment, outdoor electrical equipment, automotive exterior parts and other fields.
1.2.3 Easy Processing and High Production Efficiency
Li gorî materyalên metal, engineering plastics have the advantages of easy processing, simple production process and high production efficiency. Metal materials usually need complex processing procedures such as forging, casting, machining, which have high energy consumption, low efficiency and high cost; dema ku plastîkên endezyariyê dikarin ji hêla extrusionê ve werin hilberandin, şilkirina derzîlêdanê, lêdanê û rêbazên din, ku dikare hilberîna girseyî pêk bîne, pêvajoya hilberînê hêsan bike, xerckirina enerjiyê û lêçûna hilberînê kêm bike. Bo nimûne, çerxa pêvajoyê ya parçeyek otomotîvê ya plastîk a endezyariyê bi şilkirina derzîlêdanê tenê ji çend saniyeyan heya bi dehan saniyeyan e, dema ku çerxa pêvajoyê ya heman beşê metal dikare çend demjimêran heta çend rojan bigire.
Lebê, plastîkên endezyariyê jî hin zehmetiyên pêvajoyê hene: ew ji germbûna zêde û hilweşîna hîdrolîtîk hesas in, û heke germahiya pêvajoyê pir zêde be an dema rûniştinê pir dirêj be têne hilweşandin; vê bigire, hin plastîkên endezyariyê (wek PA) xwedan avê bilind e, ku bandorê li ser bandora pêvajoyê û kalîteya hilberê dike. Ji ber vê yekê, Pêdivî ye ku ji bo peydakirina kalîteya pêvajoyê pêdivî ye ku amûrên pêvajoyek profesyonel û teknîkên pêvajoyek zanistî bikar bînin.
1.2.4 Îstîqrara Dimensiyonel û însulasyona elektrîkê ya hêja
Plastîkên endezyariyê xwedan îstîqrara pîvanê ya baş e, û rêjeya piçûkbûnê piçûk e (fêrane 0.3%-1.5%) di dema pêvajoyê û karanîna de, ku dikare rastbûna pîvana hilberan misoger bike û ji deformasyonê dûr bixe. Ev performans bi taybetî ji bo parçeyên rast-bilind girîng e, wek girêdanên elektrîkê, hêmanên rastbûna otomotîvê, alavên tibî, etc. Stabiliya pîvana baş a plastîkên endezyariyê bi giranî ji ber krîstalbûna wan a bilind e, kişandina avê kêm (ji bilî hin celebên wekî PA) û hêzên intermolecular xurt.
Herwisa, piraniya plastîkên endezyariyê performansa insulasyona elektrîkê ya hêja heye, ku dikare performansa însulasyonê ya baş di navberek germahiyek berfireh û rêzek frekansê de bidomîne, û ne hêsan in ku elektrîk û arkê bi rê ve bibin. Ev dihêle ku plastîkên endezyariyê bi berfirehî di warên elektrîkî û elektronîkî de bikar bînin, wek board wiring, girêdanên kabloyê, connectors, relays, motor û hêmanên din ên elektrîkê.
1.2.5 Giraniya sivik û Hêza Taybet a Bilind, Berxwedana Berbiçav
Plastîkên endezyarî xwedî taybetmendiyên giraniya sivik in (density e 1/3-1/5 ji materyalên metal) û hêza taybetî ya bilind (hêza per yekîneya giraniyê ji ya materyalên metal wekhev an jî jê mezintir e). Bo nimûne, hêza taybetî ya fîbera camê ya polîamîdê xurtkirî (PA66 + GF30) ji pola karbonê ya normal bilindtir e, ku dikare bi bandor giraniya hilberan kêm bike dema ku performansa mekanîkî misoger dike. Ev performans bi taybetî di otomotîvê de girîng e, esmanî û qadên din ên ku li pey teserûfa sivik û enerjiyê ne, ku dikare mezaxtina sotemeniyê û belavbûna karbonê kêm bike.
Vê bigire, plastîkên endezyariyê di heman demê de xwedan berxwedana cil û berxwedêriya berbiçav e, û hevsengiya kêşanê piçûk e, ku dikare di hilberîna parçeyên berxwedêr ên liberxwedanê de were bikar anîn (wek gear, dordîtinî, blokên sliding) bê lubrication zêde an bi lubrication kêmtir, kêmkirina lêçûna lênêrînê ya hilberan. Bo nimûne, polyoxymethylene (POM) plastîkên endezyariyê xwedan berxwedana cilê ya hêja ye û wekî tê zanîn “pola plastîk”, ku bi berfirehî di hilberîna alavên otomotîvê de tê bikar anîn, hêmanên elektrîkê û beşên din ên liberxwedan.
1.3 Dabeşkirina hevpar a plastîkên endezyariyê
Plastîkên endezyariyê li gorî avahiya xwe ya kîmyewî li celebên cûda têne dabeş kirin, asta performansê û qada serîlêdanê. Rêbazên dabeşkirina hevpar wiha ne, ku ji bo baştir fêmkirina taybetmendiyên pêvajoyê û senaryoyên serîlêdanê yên plastîkên endezyariyê yên cihêreng dibe alîkar, û amûrên extrusion û teknîkên pêvajoyê yên guncan hilbijêrin:
1.3.1 Dabeşkirin li gorî Asta Performansê
Li gorî asta performansê, plastîkên endezyariyê dikarin li plastîkên endezyariya gelemperî û plastîkên endezyariya taybetî werin dabeş kirin.
- General Engineering Plastics: Ew plastîkên endezyariyê yên ku herî zêde têne bikar anîn in, bi teknolojiya hilberîna nisbeten gihîştî, bihayê nerm û performansa berfireh a baş. Cûreyên sereke polyamide hene (PA), polycarbonate (PC), polyoxymethylene (POM), polyethylene terephthalate (MIZDAN), polybutylen terephthalate (PBT), etc. Plastîkên endezyariya gelemperî bi gelemperî di otomobîlan de têne bikar anîn, elektrîk û elektronîk, alavên malê û qadên din, wek parçeyên otomobîlan, girêdanên elektrîkê, şêlên amûra malê, etc.
- Plastîkên Endezyariya Taybet: Ew performansa çêtir çêtir in (wek berxwedana germa bilind, berxwedana korozyonê, taybetmendiyên mekanîkî) ji plastîkên endezyariya gelemperî, lê teknolojiya hilberînê tevlihev e û biha ye. The main varieties include polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), etc. Special engineering plastics are mainly used in high-end fields such as aerospace, alavên tibî, new energy, and chemical equipment, such as aerospace components, medical implants, high-temperature resistant electrical components, etc.
1.3.2 Classification by Chemical Structure
According to the chemical structure of the molecular chain, engineering plastics can be divided into polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), polyester (MIZDAN, PBT), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), etc. Each type of engineering plastic has its own unique performance characteristics and processing requirements:
- Polyamid (PA): Also known as nylon, it has excellent mechanical strength, berxwedana wear, toughness and chemical resistance, but has high water absorption, which affects the dimensional stability. Common varieties include PA6, PA66, PA11, PA12, etc. It is widely used in automotive parts (gears, dordîtinî, intake manifolds), girêdanên elektrîkê, textile fibers, etc.
- Polycarbonate (PC): It has excellent transparency, hêza bandorê, berxwedana germê û însulasyona elektrîkê, lê xwedan berxwedana cilê ya qels e û bi hêsanî tê xêzkirin. Ew bi berfirehî di warên elektrîkê û elektronîkî de tê bikar anîn (board wiring, pêlên çirayê), zeviyên otomotîvê (lensên lampayê, panelên amûran), qadên bijîşkî (konteynerên bijîşkî), etc.
- Polyoxymethylene (POM): Ew berxwedana cilê ya hêja heye, berxwedana kêşanê, aramiya dimensî û hêza mekanîkî, û girtina avê ne hêsan e. Wek tê zanîn “pola plastîk” û bi berfirehî di parçeyên otomobîlan de tê bikar anîn (gears, blokên sliding), pêkhateyên elektrîkê (switches, dordîtinî), parçeyên mekanîk, etc.
- Polyester (MIZDAN, PBT): PET xwedan zelaliyek hêja ye, berxwedana germê û hêza mekanîkî, û bi giranî di fiberan de tê bikar anîn, filman, şûşe û zeviyên din; PBT xwedan berxwedana kîmyewî ya hêja ye, insulasyona elektrîkê û şilbûna pêvajoyê, û bi berfirehî di warên elektrîkê û elektronîkî de tê bikar anîn (connectors, relays), parçeyên otomobîlan, etc.
- Polîfenîlen Sulfîdê (PPS): Ew berxwedana germê ya hêja heye (Germahiya karanîna demdirêj heya 200-220 ℃), berxwedana korozyonê, retardancy agirê û insulasyona elektrîkê, lê dijwariya wê kêm e. Ew bi berfirehî di pêkhateyên elektrîkê yên berxwedêr ên germahiya bilind de tê bikar anîn, parçeyên motora otomobîlan, alavên kîmyewî, etc.
- Polyether Ether Ketone (PEEK): Ew performansa berfireh a hêja heye, Germahiya karanîna demdirêj heya 250-300 ℃, berxwedana korozyonê baş, hêza mekanîkî û biyokompatîbilî. Ew bi giranî di qadên bilind ên wekî hewavaniyê de tê bikar anîn, medical implants, û pêkhateyên elektrîkê yên berxwedêr ên germahiya bilind.
1.3.3 Dabeşkirin li gorî Qada Serlêdanê
Li gorî qada serîlêdanê, plastîkên endezyariyê dikare li plastîkên endezyariya pola otomotîvê were dabeş kirin, plastîkên endezyariya pola elektrîkê, plastîkên endezyariya pola bijîjkî, plastîkên endezyariya pola hewayî, etc. Qadên serîlêdanê yên cihêreng li ser performansa plastîkên endezyariyê daxwazên cûda hene. Bo nimûne, plastîkên endezyariya pola otomotîvê berxwedana germahiya baş hewce dike, hêza bandor û berxwedana hewayê; plastîkên endezyariya pola elektrîkê hewceyê însulasyona elektrîkê ya baş û paşvexistina agir hewce dike; plastîkên endezyariya pola bijîjkî bi biyolojîk û sterilbûnek baş hewce dike; plastîkên endezyariya pola hewayê hewceyê berxwedana germahiya bilind a baş e, giraniya kêm û hêza bilind.
2. Teknolojiya Pêvajoya Navendî ya Plastîkên Endezyariyê: Twin-Screw Extrusion Technology
Pêvajoya plastîkên endezyariyê bi piranî extrusion pêk tîne, şilkirina derzîlêdanê, lêdanê lêdanê, qalibandin û rêbazên din, di nav wan de teknolojiya derxistina du-pişk teknolojiya bingehîn e ji bo hilberîna pêkhateyên plastîk ên endezyariyê (wek plastîkên endezyariya guhertî, plastîkên endezyariyê yên xurtkirî) û berhemên nîv-qediyayî (wek lûle, sheets, fibers). Li gorî teknolojiya derxistina yek-screw, Teknolojiya derxistina du-screw xwedan avantajên hêza şirîn a bihêz e, bandora tevlihevkirinê ya baş, kontrola germê ya rastîn, dema rûniştinê ya kurt û adaptasyona bihêz a ji materyalên xav re, ku dikare bi bandor dijwariyên pêvajoyê yên plastîkên endezyariyê çareser bike (such as sensitivity to overheating and hydrolytic degradation, poor mixing effect, low processing efficiency) and ensure the quality of engineering plastic products.
2.1 Processing Difficulties of Engineering Plastics and Requirements for Extrusion Equipment
As mentioned earlier, engineering plastics have excellent comprehensive performance, but their processing difficulty is also higher than that of general plastics, mainly due to their special molecular structure and performance characteristics. The main processing difficulties of engineering plastics and the corresponding requirements for extrusion equipment are as follows:
2.1.1 Sensitivity to Overheating and Hydrolytic Degradation
Most engineering plastics (wek PA, PBT, PPS) are sensitive to overheating and hydrolytic degradation. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, which will reduce the mechanical properties, heat resistance and other performance of the product, and even cause discoloration, carbonization and other defects. Herwisa, hin plastîkên endezyariyê (wek PA) xwedan avê bilind e, and the moisture in the material will cause hydrolytic degradation during the high-temperature processing process, affecting the product quality.
This puts forward two key requirements for extrusion equipment: yekem, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, and the temperature control precision should reach ±1℃; duyem, dema rûniştinê ya kurt, 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 (fêrane 1-5 minutes) û kontrola germê ya rastîn, which are more suitable for engineering plastics processing than single-screw extruders (dema rûniştinê 5-10 minutes).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (wek fiber cam, fiber karbonê, talc, retardantên agir, compatibilizers) to improve the performance of the product (such as reinforcing, toughening, retardant agirê). Bo nimûne, 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. Herwisa, the modular design of the twin-screw can freely combine different screw elements (wek gihandina hêmanan, hêmanên tevlihevkirinê, hêmanên şilkirinê) 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
Di hilberandina plastîkên endezyariya bihêzkirî de (wek fiber cam xurtkirî PA, fîber karbonê PPS-ê xurtkirî), fiber cam added, fiber karbonê û guhêrbarên din xwedan serhişkiya bilind in, ku dê di dema pêvajoya derxistinê de bibe sedema cil û bergên ciddî li ser kulm û bermîlê extruder. Ger çerx û bermîl xwedan berxwedana xizaniyê ne, ew ê zû li xwe bibin, di encamê de hêza şirîn û kapasîteya tevlihevkirinê ya extruder kêm dibe, bandor li ser kalîteya hilberê dike û jiyana karûbarê amûrê kêm dike.
Ji bo vê yekê pêdivî ye ku pîvaz û bermîla extruderê ji materyalên berxwedêr-berxwedêr ên qalîteya bilind were çêkirin û ji hêla teknolojiya hilberîna pêşkeftî ve were hilanîn.. Extruderên meyên rêza HTS-ê ji bo çîp û bermîlê pola alloy-berxwedêr a îthalkirî qebûl dikin, û di bin tedawiya pêkhatî ya bimetalîkî an dermankirina pêlava lazerê de bin, ku berxwedana cil û bermîlê ya kulm û bermîlê pir çêtir dike, û dikare bi hilberandina plastîkên endezyariyê yên bihêzkirî yên bi guhêrbarên serhişkiya bilind re adapte bibe.
2.1.4 Pêdiviyên Bilind li ser Pêvajoya Fluidity û Kontrola Zextê
Hin plastîkên endezyariyê (such as PPS, PEEK) have high viscosity and poor processing fluidity, which require the extruder to have strong conveying capacity and pressure control capacity to ensure the smooth progress of extrusion. If the conveying capacity is insufficient or the pressure control is unstable, it will cause uneven extrusion speed, unstable product size, and even equipment blockage.
Twin-screw extruders have strong conveying capacity and stable pressure control capacity. The intermeshing of the twin screws can generate strong pumping force, which can effectively convey high-viscosity engineering plastic materials; vê bigire, extruder bi senzorek zextê ya rast-bilind ve tête stendine, 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, ku têkeliya gelek faktorên wekî germahiyê pêk tîne, çap, hêz û wextê rijandinê. 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, lûleyên, sheets, fibers) through the die head. Prensîba xebatê ya taybetî û herikîna pêvajoyê wiha ne:
2.2.1 Pêşdibistana Madeya Rawê
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 (wek PA, PC, POM), modifiers (wek fiber cam, fiber karbonê, talc, retardantên agir), compatibilizers, lubricants and other additives. Gavên pêşdibistanê wiha ne:
- Drying Treatment: Most engineering plastics (wek PA, PBT, PPS) xwedan avê bilind e, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, qeçikan, reduced mechanical properties). Ji ber vê yekê, berî hilberandinê divê madeyên xam bêne zuwa kirin. The drying temperature and time are determined according to the type of engineering plastic: bo nimûne, PA6 is dried at 80-100℃ for 4-6 saetan, PA66 is dried at 100-120℃ for 6-8 saetan, PBT is dried at 120-140℃ for 2-4 saetan, PPS is dried at 150-160℃ for 3-5 saetan. Pêdivî ye ku rêjeya şilbûna madeyên xav ên hişkkirî li jêr were kontrol kirin 0.1%-0.2%.
- Premixing Treatment: Li gorî rêjeya formula, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. Leza tevlihevkirinê bi gelemperî ye 800-1200 rpm, û dema tevlihevkirinê ye 5-10 minutes. 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.
- Perçiqandin û Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (wek fiber cam), 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. Mezinahiya perçeyên madeyên xav ên pelçiqandî divê were kontrol kirin 20-40 mesh.
2.2.2 Xwarin û Veguheztin
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. Amûra xwarinê ya extruder bi gelemperî bi fonksiyonek rêziknameya leza veguheztina frekansê ve tê saz kirin, ku dikare leza xwarinê li gorî leza pêlav û leza derxistinê biguhezîne da ku pê ewle bibe ku materyal bi îstîqrar û yekreng têkevin hundurê valahiya derxistinê, dûrkirina kombûna maddî an kêmxwarinê. 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, Tevlihevkirin û Parkirin
Materyalên ku dikevin valahiya derbirînê ya extrudera du-pişkan bi pêlên zivirî bi domdarî pêş de têne avêtin.. Kevirê derxistinê ji çîçek û bermîlekê pêk tê, û qebareya valahîya derbirînê gav bi gav bi rêça eksê kêm dibe. Dema ku screws zivirî, maddeyên hêdî hêdî di bin çalakiya pêçan û bermîlê de têne pêçandin, û zexta di valahiya extrusionê de hêdî hêdî zêde dibe (generally 5-15MPa).
Vê bigire, maddeyên ku ji hêla tevgera têkildar a di navbera pêçan û bermîlê de têne hilberandin di bin hêza şirîn û hêza kêşanê de têne çêkirin., her weha di navbera firînên screw de. 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. Hêza kêşanê jî dikare hejmarek germê çêbike, ku bi germkirina derve ya bermîlê re tê hev kirin (germkirina elektrîkê an germkirina buharê) to make the engineering plastic resin gradually melt and plasticize.
Bermîla extruder bi gelemperî tê dabeş kirin 4-6 beşên kontrolkirina germahiyê (beşa xwarinê, beşa helandinê, beşa tevlihevkirinê, beşa homojenkirinê, beşa serê mirinê), and the temperature of each section is precisely controlled according to the type of engineering plastic. Bo nimûne, when processing PA66+GF30 (glass fiber reinforced PA66), the temperature of the feeding section is 120-140℃, the melting section is 250-260℃, the mixing section is 260-270℃, the homogenizing section is 250-260℃, and the die head section is 240-250℃. The precise temperature control can ensure that the resin is fully melted without thermal decomposition, and the modifiers are uniformly dispersed.
2.2.4 Extrusion and Shaping
Bi tevahî heliya, maddeya têkel û belavbûyî ji hêla pêçan ve berbi serê mirinê ya extruder ve tê kişandin. Serê mirinê li gorî şiklê hilbera dawîn hatî çêkirin: ji bo hilberîna pêkhateyên plastîk ên endezyariyê (granules), serê mirinê bi kunên mirinê yên dorhêl ên pirjimar ve girêdayî ye (hejmar û mezinahiya kunên mirinê li gorî mezinahiya parçikên granulan têne destnîşankirin); ji bo hilberîna lûleyan, sheets, fibers, serê mirinê bi şêweyên têkildar têne sêwirandin (wek dimirin dorhêl ji bo lûleyan, bimirin daîre ji bo çarşefên).
Materyal ji serê mirinê bi leza bilind tê derxistin da ku hilberên nîv-qediyayî yên domdar çêbike (wek şirîtên ji bo granula, lûleyên, sheets). Germahiya serê mirinê ji ya beşa homojenkirinê hinekî kêmtir e, ku dikare pêşî li hilweşandina materyalê ji ber germahiya zêde bigire û bandora şeklê hilberên nîv-qediyayî misoger bike. Leza derxistinê li gorî celebê plastika endezyariyê û şeklê hilberê tê kontrol kirin, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, û germahiya ava sarbûnê di 20-30 ℃ de tê kontrol kirin, û dema sarbûnê ye 2-5 minutes; 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
Piştî sarbûn û hişkbûnê, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (granules), 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 (mezinahiya perçeyê bi gelemperî 2-5 mm e, ku dikare li gorî hewcedariyên xerîdar were sererast kirin). 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.
Herwisa, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (wek pir mezin, pirtikên pir piçûk an agglomerated); the inspection step is to detect the performance (such as mechanical strength, berxwedana germê, rastbûna dimensional) 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. Gelek faktor hene ku bandorê li ser bandora extrusionê dikin, bi giranî taybetmendiyên madeya xam jî tê de hene, rêjeya formula, bandora pêşdibistanê, Parametreyên extrusion û avahiya serê mirinê. Serdestkirina van faktorên sereke û çêkirina verastkirinên zanistî dikare aramiya bandora derxistinê û hevgirtina kalîteya hilberê misoger bike..
2.3.1 Taybetmendiyên madeya xam
Cureyê, size particle, naveroka şilbûn û paqijiya madeyên xav bandorek mezin li ser bandora derxistinê heye. Bo nimûne, 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%; ger ku rewa pir zêde be, it will cause hydrolytic degradation of the material and bubbles in the product. Paqijiya madeyên xam jî pir girîng e; nepakiyên di madeyên xav de (wek metal, keviran, toz) will not only affect the product quality, lê di heman demê de pîvaz û bermîla extruderê jî dixin, û tewra dibe sedema astengkirina amûran.
2.3.2 Rêjeya Formula
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. Bo nimûne, zêdekirin 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. Cûre û dosyaya lêzêdekeran jî pêdivî ye ku bi rengek maqûl were hevber kirin: 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, şilbûna pêvajoyê baştir bike, 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 Bandora Premixing
Premixing bingeha hilberîna extrusionê ye. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. Heke pêşdibistanê nehevseng be, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, tevlihevkirina neyeksan a materyalan di dema derxistinê de, and reduced product performance. Ji bo ku bandora pêşdibistanê piştrast bike, pêdivî ye ku leza tevlihevkirinê were kontrol kirin, dema tevlihevkirinê û germahiya tevlihevkirinê: the mixing speed is 800-1200 rpm, dema tevlihevkirinê ye 5-10 minutes, û germahiya tevlihevkirinê di 40-60 ℃ de tê kontrol kirin (Germahiya guncaw dikare girêdana pêvekan baştir bike û tevlihevkirina yekreng pêşve bibe).
2.3.4 Parametreyên Extrusion
Parametreyên Extrusion faktorên herî girîng in ku bandorê li ser bandora extrusion, bi giranî di nav wan de leza çolê, germahiya extrusion û zexta extrusion.
- Screw Speed: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 ber 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. Leza screw bilindtir e, hêza rijandinê û hêza xişandinê ya ku ji hêla materyalan ve tê wergirtin mezintir e, the better the mixing and dispersing effect of modifiers, û karîgeriya hilberînê bilindtir e. Lebê, ger leza çîtikê pir zêde be, dema rûniştina materyalan di valahiya derbirînê de pir kurt e, resulting in incomplete melting of the resin, tevlihevkirina têrker a materyalan, and uneven product quality; ger leza çîtikê pir kêm be, hêza rijandinê û hêza xişandinê têrê nake, the modifiers cannot be fully dispersed, û karîgeriya hilberînê kêm e. The screw speed should be adjusted according to the type of engineering plastic and the type of modifier: for high-viscosity engineering plastics (such as PPS, PEEK), a lower screw speed is needed to ensure sufficient melting and mixing; for reinforced engineering plastics (wek fiber cam xurtkirî PA), a higher screw speed is needed to ensure the uniform dispersion of glass fiber.
- Germahiya Extrusion: 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. Germahiya beşa xwarinê kêmtir e (hinekî ji germahiya zuhakirina madeyên xav bilindtir e), ku bi giranî ew e ku pêşî li kelijandina materyalan bigire û xwarina xweş peyda bike; germahiya beşa helandinê navîn e, which is mainly to promote the melting and plasticization of the resin; germahiya beşa tevlihevkirinê bilindtir e, ku bi giranî ji bo zêdekirina bandora şil û tevlihevkirinê ye, and promote the uniform dispersion of modifiers; germahiya beşa homojenkirinê ji beşa tevlihevkirinê hinekî kêmtir e, ku bi piranî ji bo misogerkirina germahîya yekgirtî û vîskozîteya materyalan e, û ji hilweşîna termal dûr bikevin; germahiya beşa serê mirinê hinekî ji beşa homojenkirinê kêmtir e, 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 Pressure: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. Zexta di valahiya derxistinê de bi giranî ji hêla rêjeya pêçanê ya pêçê ve tê destnîşankirin, size hole mirinê û leza screw. Zexta derxistinê ya bilind, bandora tevlihevkirin û belavkirina materyalan baştir e, and the denser the product. Lebê, heke zext pir zêde be, ew ê xerckirina enerjiyê û hilgirtina amûran zêde bike, û tewra dibe sedem ku serê mirinê jî asteng bike; heke zext pir kêm be, malzemeyên bi temamî nikarin bên pêçan û tevlihev, the product is loose, û performansa bêhêz e. 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, zextek extrusion bilindtir hewce ye.
2.3.5 Structure Serê Die
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 (granules), 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
Demek dirêj e em bi lêkolînê re mijûl bûne, pêşvebirin û hilberîna extruderên du-screw-performansa bilind, 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, vîskozîtî bilind) 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, Efficiency Hilberîna Bilind
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 û rêzikên HTS SUPER) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, ku ji ya extruderên du-pişk ên asayî pir bilindtir e (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.
Vê bigire, 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. Herwisa, the high speed design also greatly improves the production efficiency: bi ekstruderên asayî re danberhev, 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 minutes, which is much shorter than that of ordinary twin-screw extruders (5-10 minutes) and single-screw extruders (10-15 minutes). 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.
Herwisa, 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 Kontrolkirina Germahiya Rast, Performansa Stable
The HTS series extruders adopt an advanced intelligent temperature control system, ku dikare kontrolkirina rast a germahiya her beşê bermîl û serê mirinê pêk bîne. The temperature control precision can reach ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating and thermal decomposition of the material. Pergala kontrolkirina germahiyê bi fonksiyonek çavdêrî û alarmê ya rast-a-dem ve tête saz kirin: heke germahiya her beşê ji rêza destnîşankirî derbas bibe, pergal dê di wextê xwe de hişyariyek alarmê bide, û tewra bixweber hêza germkirinê rast bikin an ger hewce bike amûran bişkînin, da ku ji têkçûna alavên û pirsgirêkên kalîteya hilberê dûr bixin.
Herwisa, the barrel of the HTS series extruders adopts a double-layer jacket design, ku dikare germbûn û sarbûna bilez pêk bîne, û leza bersivê ya kontrolkirina germahiyê baştir bikin. Serê mirinê di heman demê de bi amûrek kontrolkirina germahiyê ya serbixwe ve tê stend, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 Bandora Tevlihevkirin û Belavkirinê ya Berbiçav
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, bi piçikek maqûl, sêwirana rêjeya rêber û compression. Têkilî û zivirîna pêlên cêwî dikare hêza şirînê û hêza hevîrkirinê çêbike., which can fully break the agglomerates of modifiers (wek fiber cam, fiber karbonê, talc), 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%, ku ji ya extruderên du-pişk ên asayî pir bilindtir e (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (wek gihandina hêmanan, hêmanên tevlihevkirinê, hêmanên şilkirinê) can be freely combined according to the type of engineering plastic and modifier. Bo nimûne, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (such as PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 Berxwedana Wear High, Jiyana Xizmeta Dirêj
Di hilberandina plastîkên endezyariya bihêzkirî de (wek fiber cam xurtkirî PA, fîber karbonê PPS-ê xurtkirî), 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 (wek 38CrMoAlA), û di bin tedawiya pêkhatî ya bimetalîkî an dermankirina pêlava lazerê de bin. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) û ≥70 HRC (HTS PLUS series û rêzikên HTS SUPER), ku xwedan berxwedana liberxwedan û berxwedana korozyonê ya pir xurt e, and can effectively resist the wear caused by high-hardness modifiers. Ev pir dirêjkirina jiyana karûbarê kêş û bermîlê dirêj dike: the service life of the screw and barrel of the HTS series extruders is 2-3 caran ji extruders asayî, kêmkirina frekansa guheztina pêkhateyan û lêçûna lênihêrîna amûrê.
Herwisa, em di heman demê de karûbarên tespîtkirina cil û bergên profesyonel ên ji bo kulm û bermîlê jî peyda dikin. Tîmê meya teknîkî dê bi rêkûpêk asta kincan a çîp û bermîlê ji bo xerîdaran tespît bike, raporek kincên berfireh derxînin, û pêşniyarên guheztin û lênêrînê yên armanckirî derxînin pêş, temînkirina ku xerîdar tenê gava ku hewce be pêkhateyan diguhezînin, dûrketina ji bermahiyên nehewce.
3.1.6 Berfirehiya Serlêdanê, Flexibility Strong
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, MIZDAN, 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, etc.
The modular design of the HTS series extruders (badan, kûp, serê mirinê, etc.) guheztina pêkhateyan hêsantir û bileztir dike. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, ew tenê hewce ne ku pêkhateyên têkildar biguhezînin, bêyî ku tevahiya amûran biguherînin, ku lêçûna veguherîna amûrê kêm dike û nermbûn û adaptasyona amûrê çêtir dike. Herwisa, the HTS series extruders can also be matched with different auxiliary equipment (wek mîkserên bi leza bilind, dryers, sarkeran, granulators, makîneyên vekolînê, makîneyên pakkirinê) ji bo avakirina xeta hilberîna otomatîkî ya bêkêmasî, pêkanîna hilberîna domdar ji pêşdibistanên madeya xav heya pakkirina hilberê.
3.1.7 Control Intelligent, Operasyon û Maintenance Easy
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, ku sade û têgihîştî ye, bi hêsanî kar. Pergal dikare gelek komikên formulên hilberê û parametreyên pêvajoyê hilîne. When customers produce different types of engineering plastics, they only need to call the corresponding formula and parameters, bêyî debugging dubare, ku dem xilas dike û karbidestiya hilberînê çêtir dike.
Pergal di heman demê de bi fonksiyonek çavdêriya rast-demê jî tê stend, ku dikare pîvanên sereke yên pêvajoya derxistinê bişopîne (wek germahî, çap, speed screw, leza xwarinê) di dema rast de, û daneyên hilberînê tomar bikin (wek encam, dema pêvajoyê) ji bo pirs û analîzên paşê. Ji bo extruders series HTS SUPER, em di heman demê de fonksiyonek kontrola ewr jî peyda dikin, ku dikare verastkirina parametreyê ji dûr ve pêk bîne, çavdêriya daneya hilberînê û lênihêrîna pêşbînîkirî ya amûran, pêkanîna rêveberiya hilberîna aqilmend.
Herwisa, the HTS series extruders adopt a reasonable structural design, ku lênêrînê hêsantir dike. The screw, kûp, die head and other components can be disassembled and assembled quickly, ku dema lênêrînê û giraniya kedê kêm dike. Our after-sales service team will provide professional installation, karûbarên komîsyonê û perwerdehiyê ji bo xerîdaran, temînkirina ku xerîdar dikarin amûrê bi hêsanî bikar bînin.
3.2 HTS Series Extruder Product Types and Their Adaptation to Engineering Plastics
In order to meet the diverse processing needs of engineering plastics enterprises of different scales and product types, we have launched three main product types in the HTS series: HTS BASIC series, HTS PLUS series û rêzikên HTS SUPER. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, cureyê berhemê, budget and other factors.
3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. Ev rêzeya extruderan ji hilberînerên pêşeng ên Ewropî gearboxên torque navîn bikar tîne, ku xwedî avantajên performansa stabîl in, dengê kêm, karîgeriya bilind û jiyana karûbarê dirêj. The medium-torque design (specific torque 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, MIZDAN, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
Di warê sêwirana avahîsaziyê de, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, bi diameter screw bibitin ji 30mm ber 65mm, û rêjeya kompresyonê ya 4～8, which can be adjusted according to the type of engineering plastic. Bermîl ji pola alloy-berxwedêr a bi dermankirina nitriding ve hatî çêkirin, û çîp ji pola alloy-berxwedêr û berxwedêr-berxwedêr tê çêkirin, ku berxwedana cilê baş heye. Extruder bi pergalek kontrolê ya PLC û navgînek xebitandina ekrana desta ve tê stend, ku dikare xwarina otomatîkî pêk bîne, kontrola germahiya otomatîk, kontrolkirina zexta otomatîk û qutkirina otomatîk, û xebitandina hêsan û hêsan e.
Kapasîteya hilberîna extruderên rêza HTS BASIC ji 100kg / h heya 500 kg / h diguhere, 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. Yek ji avantajên herî mezin ên vê rêzê ev e ku ew dikare vebijarkên maqûl bi navgîniya vesazkirina cihêreng peyda bike. Xerîdar dikarin hêmanên çolê yên cûda hilbijêrin, bimirin serî, alavên xwarinê, cîhazên zuwakirinê û alavên paş-pêvajoyê li gorî celebên hilberên xwe, kapasîteya hilberînê û budceya, da ku ji bo hewcedariyên xwe xetek hilberînê ava bikin. Extruders series HTS BASIC bihayek maqûl heye, which can help enterprises reduce the initial investment cost.
3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastics and Modified Products
Extruderên rêza HTS PLUS gearboksên torque-a bilind ku serbixwe ji hêla me ve hatî pêşve xistin û çêkirin qebûl dikin, with a specific torque of 14Nm/cm³, which has stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～800 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (surface hardness ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, fîber karbonê PPS-ê xurtkirî) and high-hardness modifiers. The extruder is equipped with an advanced intelligent temperature control system and a high-precision pressure sensor, which can realize precise control of extrusion parameters and real-time monitoring of production data, ensuring the stability of the extrusion process and the quality of the product.
The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics
The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (wek PEEK, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, high performance and intelligence.
Extruderên rêza HTS SUPER xwedan pîvazek pêçek e ku ji 80 mm heya 130 mm e., rêjeya kompresyonê ya 6-12, and a screw speed range of 250～1000 rpm. Pişk û bermîl teknolojiya pêlava pêlavê ya lazer û pêlavê ya pêlav-berxwedêr a îthalkirî qebûl dikin, ku xwedan berxwedana liberxwedan û berxwedana korozyonê pir zêde ye (surface hardness ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. Extruder bi PLC-ya jîr tê stend + cloud touch screen control system, ku dikare verastkirina parametreyê ji dûr ve pêk bîne, çavdêriya daneyên hilberînê, predictive maintenance of equipment and data analysis, pêkanîna rêveberiya hilberîna aqilmend.
Kapasîteya hilberînê ya extruderên rêza HTS SUPER ji 1000kg / h heya 3000kg / h diguhere, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minutes) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Herwisa, 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, pêdivî ye ku pargîdanî bi berfirehî hewcedariyên hilberîna xwe bifikirin, cureyên berhemên, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. Li jêr hin pêşniyarên hilbijartinê yên taybetî hene:
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, MIZDAN, 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 (mîqdara dagirtina 30%-50%, wek fiber cam xurtkirî PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (such as PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (PEEK, PI, PSU, PES) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), the HTS SUPER series must be selected. Its ultra-high torque, maximum 1000rpm speed and fully optimized key structure can cope with the high viscosity, high temperature resistance and strict processing requirements of high-end materials, avoid thermal decomposition and material degradation, and ensure the high performance of the final product.
3.3.2 Determine the Screw Diameter and Production Capacity According to the Processing Scale
The screw diameter of the twin-screw extruder directly determines the production capacity, and enterprises need to select the appropriate screw diameter according to their own production scale and order demand. For small-scale production (100kg/h – 500kg/h), such as small-batch customization, product research and development or small orders, the HTS BASIC series with screw diameter of 30mm – 65mm is suitable; for medium-scale production (500kg/h – 2000kg/h), such as mass production of general modified engineering plastics, the HTS PLUS series with screw diameter of 65mm – 110mm can meet the demand; 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 (wek retardantên agirê, compatibilizers, reinforcing agents) vê bigire, 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. Bo nimûne, 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. Herwisa, 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. Herwisa, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, di nav de sazkirinê, komîsyonkirin, perwerdeya teknîkî, 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, etc. 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. Bo nimûne, 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
Endezyariya plastîk, with their excellent comprehensive performance, have been widely used in automotive, elektrîk û elektronîk, pizişkî, asmanî, şîmyakî, 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. Jêrîn, 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: Lightweight, 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, etc., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: sivik, berxwedana germahiya bilind, berxwedana wear, dimensional stability and low VOC (pêkhateyên organîk ên guhêrbar), 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, panelên derî, air ducts) made of general engineering plastics (PA6, POM, PC/ABS alloy), the HTS BASIC series extruders can meet the processing needs. Its flexible configuration can adjust the processing parameters according to the performance requirements of interior parts, ensure the smooth surface and dimensional stability of the product, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66 + GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (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.
Lêkolîna Case: 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 minutes) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. Piştî bikaranîna extruders series HTS SUPER, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% ber 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Electrical Insulation, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Engineering plastics are mainly used in electrical connectors, board wiring, relays, motors, girêdanên kabloyê, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, retardancy agirê, îstîqrara dimensional, 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, connectors) 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, etc., which are mainly used in medical containers, kateterên tibî, medical implants, surgical instruments and other products. The core requirements for extrusion processing are: rastbûna bilind, no pollution, performansa stabîl, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (wek konteynerên bijîşkî, 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, medical implants) made of medical-grade special engineering plastics (pizîşkî-pola 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 (Pratîka Hilberîna Baş) 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, etc., 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, performansa stabîl, 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, berxwedana wear, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), etc., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: berxwedana korozyonê, berxwedana wear, performansa stabîl, 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, ji ber bandora madeyên xav, processing parameters, equipment performance and other factors, gelek caran pirsgirêkên cuda çêdibin, which affect the product quality and production efficiency. Jêrîn, 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, bubbles, 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. Leza kêşanê pir kêm e, 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 (rastbûna kontrolkirina germahiyê ± 1℃) to avoid local overheating; 2. Leza pêlê bi rêkûpêk zêde bikin (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 minutes; 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 (wek fiber cam, fiber karbonê), and the mechanical properties (qawet, dijwarî, berxwedana wear) 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. Leza kêşanê pir kêm e, 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. Germahiya derxistinê pir kêm e, 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, leza tevlihevkirinê zêde bike (800-1200rpm) and mixing time (5-10 minutes), 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. Leza pêlê bi rêkûpêk zêde bikin, 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 (wek fiber cam, fiber karbonê) on the screw and barrel during the processing of reinforced engineering plastics.
Causes: 1. Pîrek û bermîl ji materyalên bi berxwedana cilê ya nebaş têne çêkirin, 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. Extruders bi berxwedana wear bilind Select, 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) û ≥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. Herwisa, our professional technical team can provide regular wear detection services for the screw and barrel, û pêşniyarên guheztin û lênêrînê yên armanckirî derxînin pêş.
5.4 Problem 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, lûleyên, sheets) 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. Pêvajoya sarbûnê çêtir bikin, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 minutes) 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. Leza kêşanê pir kêm e, kapasîteya veguhestinê têrê nake; 2. Germahiya derxistinê pir kêm e, 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, kapasîteya veguhestinê kêm dibe, and the energy consumption is increased.
Solutions: 1. Leza pêlê bi rêkûpêk zêde bikin (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. Herwisa, the HTS series extruders adopt an optimized structural design and high-efficiency motor, ku dikare xerckirina enerjiyê kêm bike 15%-20% bi ekstruderên asayî re danberhev.
6. Conclusion and Future Development Trend
Endezyariya plastîk, wekî materyalek sereke ya performansa bilind, 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, karîgeriya hilberînê û bandora serîlêdana hilberên plastîk ên endezyariyê. 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, vîskozîtî bilind), with the advantages of high torque, leza bilind, kontrola germê ya rastîn, berxwedana wear baş, 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.
Li hêviya pêşerojê, with the continuous upgrading of downstream industries such as automotive lightweight, îstîxbarata elektrîkê û elektronîk, new energy and medical high-endization, daxwaza ji bo performansa bilind, 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:
Yekem, 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. Vê bigire, 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.
Duyem, high performance and high efficiency. The demand for high-end engineering plastics (wek 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 (badan, kûp, gearbox) will be further optimized to improve wear resistance, corrosion resistance and service life. Vê bigire, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Sêyem, 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. Vê bigire, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Çarem, 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; vê bigire, 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.