Pẹlu ilọsiwaju iyara ti iṣelọpọ agbaye, ibeere fun awọn ohun elo iṣẹ ṣiṣe giga ni ọkọ ayọkẹlẹ, itanna ati itanna, ikole, oogun ati awọn aaye miiran n pọ si lojoojumọ. Awọn pilasitik ẹrọ, bi bọtini iṣẹ ṣiṣe giga, ti rọpo awọn ohun elo irin ibile ati awọn pilasitik gbogbogbo ni ọpọlọpọ awọn oju iṣẹlẹ ohun elo mojuto nitori awọn ohun-ini ẹrọ ti o dara julọ, ooru resistance, ipata resistance, onisẹpo iduroṣinṣin ati processability. Imọ-ẹrọ extrusion Twin-skru jẹ imọ-ẹrọ sisẹ mojuto ti awọn agbo ogun ṣiṣu ina-ẹrọ, ati awọn iṣẹ ti extrusion ẹrọ taara ipinnu awọn didara, ṣiṣe iṣelọpọ ati ipa ohun elo ti awọn ọja ṣiṣu ẹrọ.
A ti pinnu lati pese awọn solusan extrusion twin-skru ọjọgbọn fun ṣiṣe awọn pilasitik ina-ẹrọ, da lori ominira wa ni idagbasoke ati ti ṣelọpọ HTS jara extruders pẹlu ga-yipo gearboxes, eyiti o jẹ apẹrẹ pataki fun awọn abuda sisẹ ati awọn iwulo ohun elo ti awọn pilasitik ẹrọ. Nkan yii yoo ṣe alaye ni kikun lori awọn abuda iṣẹ, isọri, awọn iṣoro ṣiṣe ti awọn pilasitik ẹrọ, ipa pataki ti imọ-ẹrọ extrusion twin-skru ni sisẹ awọn pilasitik ẹrọ, awọn anfani ti wa HTS jara extruders ati awọn won ìfọkànsí aṣamubadọgba si ina- pilasitik, bakannaa awọn aaye ohun elo pato, processing imuposi ati wọpọ isoro ati awọn solusan. Nipa afikun awọn ipilẹ imọ-ẹrọ alaye, awọn alaye processing ati awọn ọran ohun elo ile-iṣẹ, article yoo wa ni idarato si 3000-4000 awọn ọrọ, pese okeerẹ ati itọkasi ọjọgbọn fun awọn ile-iṣẹ iṣelọpọ pilasitik ẹrọ, technicians ati ti o yẹ awọn oṣiṣẹ.
1. Akopọ ti Engineering Plastics Industry ati Core Performance Abuda
1.1 Ipo lọwọlọwọ ati Ilọsiwaju Idagbasoke ti Ile-iṣẹ pilasitik Imọ-ẹrọ
Awọn pilasitik ti imọ-ẹrọ tọka si kilasi ti awọn ohun elo ṣiṣu ti o le ṣee lo bi awọn ohun elo igbekalẹ ati jẹri awọn ẹru ẹrọ ni iwọn otutu jakejado.. Akawe pẹlu gbogbo pilasitik (gẹgẹ bi awọn polyethylene PE, polypropylene PP, polyvinyl kiloraidi PVC), pilasitik ina- ni diẹ o tayọ okeerẹ išẹ, ati pe o le pade awọn ibeere lilo lile ni iṣelọpọ ile-iṣẹ ati iṣelọpọ ọja giga-giga. Ni awọn ọdun aipẹ, ìṣó nipasẹ awọn igbegasoke ti ibosile ile ise bi Oko lightweight, itanna ati itanna itetisi, ati egbogi ẹrọ ga-opin, ọja pilasitik ẹrọ agbaye ti ṣe afihan aṣa idagbasoke ti o duro ati iyara.
Gẹgẹbi data ile-iṣẹ ti o yẹ, iwọn ọja pilasitik ina-ẹrọ ti kọja 100 bilionu owo dola Amerika, ati awọn ti o ti wa ni o ti ṣe yẹ lati ṣetọju a yellow lododun idagba oṣuwọn ti 7%-10% ni odun marun to nbo. Lára wọn, Asia-Pacific jẹ iṣelọpọ pilasitik ti imọ-ẹrọ ti o tobi julọ ni agbaye ati ọja lilo, iṣiro fun diẹ ẹ sii ju 55% ti agbaye oja ipin, nipataki nitori idagbasoke iyara ti ọkọ ayọkẹlẹ, itanna ati ẹrọ itanna ise ni China, India ati awọn orilẹ-ede miiran, bii ilọsiwaju ilọsiwaju ti agbara atilẹyin ile-iṣẹ ati ipele imotuntun imọ-ẹrọ. China, bi olumulo pilasitik ẹrọ imọ-ẹrọ ti o tobi julọ ni agbaye ati olupilẹṣẹ, ni ibeere ọja nla kan, ati iṣelọpọ ọdọọdun ati agbara n dagba ni iwọn oni-nọmba meji, paapaa ni awọn aaye ti awọn ọkọ ayọkẹlẹ agbara titun, 5G awọn ibaraẹnisọrọ, ati awọn ẹrọ iwosan, ibeere fun awọn pilasitik imọ-ẹrọ iṣẹ-giga n ṣafihan aṣa idagbasoke ibẹjadi.
Aṣa idagbasoke ti ile-iṣẹ pilasitik ẹrọ jẹ afihan ni akọkọ ni awọn aaye marun: akọkọ, ga išẹ ati functionalization. Pẹlu ilọsiwaju ilọsiwaju ti awọn ibeere lilo ni awọn aaye isalẹ, awọn pilasitik ti ẹrọ n dagbasoke si ọna resistance ooru ti o ga julọ, ti o ga agbara, dara yiya resistance ati ki o pataki awọn iṣẹ (bii idaduro ina, antistatic, antibacterial, ipanilara resistance), lati ṣe deede si agbegbe iṣẹ lile ti iwọn otutu giga, ga titẹ, ipata ati Ìtọjú; keji, lightweight ati Integration. Ninu ọkọ ayọkẹlẹ, Aerospace ati awọn aaye miiran, lati le ṣaṣeyọri fifipamọ agbara ati awọn ibi-afẹde idinku itujade, pilasitik ina-ẹrọ ti wa ni lilo siwaju sii lati rọpo awọn ohun elo irin, ati isọpọ ti apẹrẹ ọja n di giga ati giga, eyi ti o le din awọn nọmba ti awọn ẹya ara, simplify ilana iṣelọpọ ati dinku awọn idiyele; kẹta, Idaabobo ayika ati atunlo. Pẹlu okun ti awọn eto imulo aabo ayika agbaye ati ilọsiwaju ti imọ aabo ayika, idagbasoke ati ohun elo ti awọn pilasitik ti imọ-ẹrọ atunlo, pilasitik imọ-ẹrọ biodegradable ati awọn imọ-ẹrọ ṣiṣe ore ayika ti di idojukọ ti ile-iṣẹ naa, idinku idoti ayika ti o ṣẹlẹ nipasẹ egbin ṣiṣu; kẹrin, oye ati konge ti processing ẹrọ. Awọn pilasitik ti ẹrọ ni iṣoro sisẹ giga ati awọn ibeere didara to muna, eyi ti o fi awọn ibeere ti o ga julọ siwaju sii lori awọn ẹrọ isise. Oloye, kongẹ ati lilo daradara ibeji-skru extruders ati ki o laifọwọyi gbóògì ila ti di atijo ti awọn ile ise, mimojuto gidi-akoko monitoring, Atunṣe paramita laifọwọyi ati itọju asọtẹlẹ ti ilana ṣiṣe; karun, diversification ti awọn aaye elo. Awọn pilasitik ti imọ-ẹrọ n pọ si diẹdiẹ lati inu ọkọ ayọkẹlẹ ibile, itanna ati itanna aaye si titun agbara, oogun, ofurufu, ikole ati awọn miiran nyoju oko, nsii soke titun oja aaye.
Lodi si yi lẹhin, ibeji-dabaru extrusion ọna ẹrọ, bi awọn mojuto processing ọna ẹrọ ti ina- ṣiṣu agbo, ti di bọtini si ilọsiwaju ifigagbaga ti awọn ile-iṣẹ pilasitik ti ẹrọ. Awọn pilasitik ti imọ-ẹrọ jẹ ifarabalẹ si igbona pupọ ati ibajẹ hydrolytic, ati ki o ni ga awọn ibeere lori processing otutu, agbara rirun, akoko ibugbe ati iwọn otutu iṣakoso konge. Awọn extruders jara HTS wa jẹ apẹrẹ pataki fun awọn abuda sisẹ ti awọn pilasitik ẹrọ, pẹlu ga iyipo, ere giga, kongẹ otutu iṣakoso ati ki o tayọ dispersibility, eyiti o le yanju ni imunadoko awọn iṣoro sisẹ ti awọn pilasitik ẹrọ ati ṣe iranlọwọ fun awọn ile-iṣẹ lati ṣaṣeyọri didara giga, iṣelọpọ daradara ati iduroṣinṣin.
1.2 Mojuto Performance Abuda ti Engineering pilasitik
Ti a ṣe afiwe pẹlu awọn pilasitik gbogbogbo ati awọn ohun elo irin, pilasitik ina- ni awọn iṣẹ okeerẹ alailẹgbẹ, eyi ti ipinnu wọn jakejado ohun elo ni orisirisi ise oko. Awọn abuda iṣẹ ṣiṣe pataki ti awọn pilasitik ina-ẹrọ jẹ afihan ni akọkọ ni awọn aaye marun wọnyi, eyiti o tun gbe awọn ibeere pataki siwaju fun imọ-ẹrọ iṣelọpọ ati ẹrọ wọn:
1.2.1 O tayọ Heat Resistance ati Tutu Resistance
Awọn pilasitik ina-ẹrọ ni iwọn isọdi iwọn otutu jakejado, eyi ti o le bojuto ti o dara darí-ini (agbara, lile, lile) ni mejeeji giga ati iwọn otutu agbegbe. Akawe pẹlu gbogbo pilasitik, eyiti o padanu awọn ohun-ini ẹrọ wọn nigbagbogbo ni 80-120 ℃, Pupọ julọ awọn pilasitik imọ-ẹrọ le ṣiṣẹ ni iduroṣinṣin ni 100-250 ℃, ati diẹ ninu awọn pilasitik imọ-ẹrọ pataki (bii PEEK, PI) le paapaa ṣiṣẹ ni awọn iwọn otutu ju 300 ℃. Ni akoko kan naa, pilasitik ẹrọ tun ni o dara tutu resistance, eyi ti o le ṣetọju toughness ti o dara ni awọn iwọn otutu kekere (labẹ -40 ℃), ati ki o wa ko rorun lati brittle dida egungun. Išẹ yii jẹ ki awọn pilasitik ti imọ-ẹrọ dara fun lilo ni awọn agbegbe iwọn otutu lile, gẹgẹ bi awọn ẹya ara ẹrọ mọto (ga otutu) ati ita gbangba itanna itanna (kekere otutu).
Iyara ooru ti o dara julọ ti awọn pilasitik ina-ẹrọ jẹ nipataki nitori eto molikula pataki wọn (gẹgẹbi awọn oruka ti oorun didun, heterocyclic oruka) ati ki o lagbara intermolecular ologun, eyi ti o mu ki wọn ko rọrun lati yo ati decompose ni awọn iwọn otutu giga. Sibẹsibẹ, eyi tun mu awọn iṣoro kan wa si sisẹ: ti o ga processing otutu ni ti a beere lati ṣe wọn yo ati plasticize, ati iṣakoso iwọn otutu deede nilo lati yago fun jijẹ gbigbona.
1.2.2 Resistance Ipata ti o dara ati Agbara
Awọn pilasitik ti imọ-ẹrọ ni iduroṣinṣin kemikali ti o dara julọ ati resistance ipata, ati pe ko rọrun lati jẹ ibajẹ nipasẹ awọn acids, alkalis, iyọ, Organic epo ati awọn miiran kemikali. Ti a ṣe afiwe pẹlu awọn ohun elo irin, eyi ti o rọrun lati ipata ati ibajẹ, pilasitik ẹrọ ni igbesi aye iṣẹ to gun ni awọn agbegbe kemikali simi. Fun apere, polyamide (PA) awọn pilasitik ti imọ-ẹrọ jẹ sooro si ọpọlọpọ awọn olomi Organic ati awọn acids alailagbara ati alkalis; polycarbonate (PC) awọn pilasitik ti imọ-ẹrọ jẹ sooro si ipata nipasẹ awọn acids ti kii ṣe oxidizing ati iyọ; polyphenylene sulfide (PPS) pilasitik ti ina- jẹ sooro si ipata nipasẹ fere gbogbo awọn kemikali ayafi awọn acids oxidizing lagbara.
Ni afikun, awọn pilasitik ti imọ-ẹrọ ni aabo oju ojo ti o dara ati resistance ti ogbo, ati pe ko rọrun lati dinku ati ọjọ ori labẹ iṣẹ ti oorun, ojo, atẹgun ati awọn ifosiwewe ayika miiran, eyiti o ṣe idaniloju lilo iduroṣinṣin igba pipẹ wọn ni ita ati awọn agbegbe lile. Iṣe yii jẹ ki awọn pilasitik ina-ẹrọ ni lilo pupọ ni ohun elo kemikali, ita gbangba itanna itanna, Oko ayọkẹlẹ ita awọn ẹya ara ati awọn miiran oko.
1.2.3 Ṣiṣe irọrun ati ṣiṣe iṣelọpọ giga
Ti a ṣe afiwe pẹlu awọn ohun elo irin, awọn pilasitik ẹrọ ni awọn anfani ti sisẹ irọrun, ilana iṣelọpọ ti o rọrun ati ṣiṣe iṣelọpọ giga. Awọn ohun elo irin nigbagbogbo nilo awọn ilana iṣelọpọ eka gẹgẹbi ayederu, simẹnti, ẹrọ, eyi ti o ni ga agbara agbara, kekere ṣiṣe ati ki o ga iye owo; lakoko ti awọn pilasitik ina-ẹrọ le ṣe ilọsiwaju nipasẹ extrusion, abẹrẹ igbáti, fe igbáti ati awọn miiran awọn ọna, eyi ti o le mọ ibi-gbóògì, simplify the production process, reduce energy consumption and production cost. Fun apere, 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.
Sibẹsibẹ, 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; ni akoko kan naa, diẹ ninu awọn pilasitik ina- (bii PA) ni gbigba omi ti o ga, which affects the processing effect and product quality. Nitorina, it is necessary to use professional processing equipment and scientific processing techniques to ensure the processing quality.
1.2.4 Excellent Dimensional Stability and Electrical Insulation
Engineering plastics have good dimensional stability, and the shrinkage rate is small (nigbagbogbo 0.3%-1.5%) during processing and use, which can ensure the dimensional accuracy of products and avoid deformation. This performance is particularly important for high-precision parts, such as electrical connectors, automotive precision components, egbogi awọn ẹrọ, ati be be lo. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) ati ki o lagbara intermolecular ologun.
Ni afikun, most engineering plastics have excellent electrical insulation performance, which can maintain good insulation performance in a wide temperature range and frequency range, and are not easy to conduct electricity and arc. This makes engineering plastics widely used in electrical and electronic fields, such as wiring boards, cable ties, awọn asopọ, relays, motors and other electrical components.
1.2.5 Light Weight and High Specific Strength, Dayato si wọ Resistance
Awọn pilasitik ti ẹrọ ni awọn abuda ti iwuwo ina (iwuwo ni 1/3-1/5 ti irin ohun elo) ati ki o ga pato agbara (Agbara fun iwuwo ẹyọkan jẹ deede si tabi paapaa ga ju ti awọn ohun elo irin lọ). Fun apere, awọn pato agbara ti gilasi okun fikun polyamide (PA66 + GF30) jẹ ti o ga ju ti arinrin erogba irin, eyi ti o le fe ni din àdánù ti awọn ọja nigba ti aridaju awọn darí iṣẹ. Iṣe yii ṣe pataki ni pataki ninu ọkọ ayọkẹlẹ, Aerospace ati awọn aaye miiran ti o lepa iwuwo fẹẹrẹ ati fifipamọ agbara, eyi ti o le din idana agbara ati erogba itujade.
Ni akoko kan naa, awọn pilasitik ti imọ-ẹrọ tun ni resistance yiya ti iyalẹnu ati resistance ija, ati awọn edekoyede olùsọdipúpọ ni kekere, eyi ti o le ṣee lo ni isejade ti yiya-sooro awọn ẹya ara (gẹgẹ bi awọn jia, bearings, sisun ohun amorindun) without additional lubrication or with less lubrication, reducing the maintenance cost of products. Fun apere, 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, performance level and application field. The common classification methods are as follows, which helps to better understand the processing characteristics and application scenarios of different engineering plastics, ati ki o yan yẹ extrusion itanna ati processing imuposi:
1.3.1 Classification by Performance Level
According to the performance level, engineering plastics can be divided into general engineering plastics and special engineering plastics.
- General Engineering Plastics: They are the most widely used engineering plastics, with relatively mature production technology, moderate price and good comprehensive performance. The main varieties include polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), terephthalate polyethylene (PET), polybutylene terephthalate (PBT), ati be be lo. General engineering plastics are mainly used in automotive, itanna ati itanna, home appliances and other fields, gẹgẹbi awọn ẹya ara ẹrọ, itanna asopo, awọn ikarahun ohun elo ile, ati be be lo.
- Special Engineering Plastics: They have more excellent performance (such as higher heat resistance, ipata resistance, darí-ini) than general engineering plastics, but the production technology is complex and the price is high. The main varieties include polyphenylene sulfide (PPS), polyether ether ketone (WO), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), ati be be lo. Special engineering plastics are mainly used in high-end fields such as aerospace, egbogi awọn ẹrọ, new energy, and chemical equipment, such as aerospace components, medical implants, high-temperature resistant electrical components, ati be be lo.
1.3.2 Isọri nipasẹ Kemikali Be
Ni ibamu si awọn kemikali be ti awọn molikula pq, awọn pilasitik ina-ẹrọ le pin si polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), poliesita (PET, PBT), polyphenylene sulfide (PPS), polyether ether ketone (WO), ati be be lo. Kọọkan iru ṣiṣu ina- ni o ni awọn oniwe-ara oto išẹ abuda ati processing awọn ibeere:
- Polyamide (PA): Tun mo bi ọra, o ni o ni o tayọ darí agbara, wọ resistance, toughness ati kemikali resistance, sugbon o ni ga omi gbigba, eyi ti yoo ni ipa lori iduroṣinṣin onisẹpo. Awọn orisirisi ti o wọpọ pẹlu PA6, PA66, PA11, PA12, ati be be lo. O ti wa ni o gbajumo ni lilo ninu Oko awọn ẹya ara (murasilẹ, bearings, gbigbemi ọpọlọpọ), itanna asopo, aso awọn okun, ati be be lo.
- Polycarbonate (PC): O ni o tayọ akoyawo, agbara ipa, ooru resistance ati itanna idabobo, sugbon ko dara yiya resistance ati ki o jẹ rorun lati ibere. O jẹ lilo pupọ ni itanna ati awọn aaye itanna (onirin lọọgan, atupa eeni), oko oko (headlamp tojú, irinse paneli), awọn aaye iwosan (egbogi awọn apoti), ati be be lo.
- Polyoxymethylene (POM): O ni o ni o tayọ yiya resistance, friction resistance, dimensional stability and mechanical strength, and is not easy to absorb water. It is known as “plastic steel” ati pe o gbajumo ni lilo ninu awọn ẹya ara ẹrọ (murasilẹ, sisun ohun amorindun), itanna irinše (awọn iyipada, bearings), darí awọn ẹya ara, ati be be lo.
- Polyester (PET, PBT): PET has excellent transparency, heat resistance and mechanical strength, and is mainly used in fibers, awọn fiimu, bottles and other fields; PBT has excellent chemical resistance, electrical insulation and processing fluidity, and is widely used in electrical and electronic fields (awọn asopọ, relays), ọkọ ayọkẹlẹ awọn ẹya ara, ati be be lo.
- Polyphenylene Sulfide (PPS): O ni o ni o tayọ ooru resistance (long-term use temperature up to 200-220℃), ipata resistance, flame retardancy and electrical insulation, but has poor toughness. It is widely used in high-temperature resistant electrical components, automotive engine parts, chemical equipment, ati be be lo.
- Polyether Ether Ketone (WO): It has excellent comprehensive performance, long-term use temperature up to 250-300℃, good corrosion resistance, mechanical strength and biocompatibility. O ti wa ni o kun lo ni ga-opin aaye bi Aerospace, medical implants, ati awọn paati itanna sooro iwọn otutu giga.
1.3.3 Iyasọtọ nipasẹ aaye Ohun elo
Ni ibamu si aaye ohun elo, awọn pilasitik ina-ẹrọ ni a le pin si awọn pilasitik ẹrọ imọ-ẹrọ adaṣe, pilasitik-ẹrọ itanna, pilasitik-ẹrọ imọ-ẹrọ, pilasitik-ẹrọ ti afẹfẹ, ati be be lo. Awọn aaye ohun elo oriṣiriṣi ni awọn ibeere oriṣiriṣi lori iṣẹ ti awọn pilasitik ẹrọ. Fun apere, Awọn pilasitik imọ-ẹrọ adaṣe nilo resistance ooru to dara, ipa agbara ati oju ojo resistance; Awọn pilasitik ẹrọ imọ-ẹrọ itanna nilo idabobo itanna to dara ati idaduro ina; pilasitik-ẹrọ imọ-ẹrọ iṣoogun nilo ibaamu biocompatibility ti o dara ati ailesabiyamo; Awọn pilasitik imọ-ẹrọ ti afẹfẹ nilo itọju iwọn otutu to dara, kekere àdánù ati ki o ga agbara.
2. Mojuto Processing Technology ti Engineering pilasitik: Twin-dabaru extrusion Technology
Ṣiṣe awọn pilasitik ina-ẹrọ ni akọkọ pẹlu extrusion, abẹrẹ igbáti, fe igbáti, mimu ati awọn ọna miiran, laarin eyiti imọ-ẹrọ extrusion twin-skru jẹ imọ-ẹrọ mojuto fun iṣelọpọ awọn agbo ogun ṣiṣu ina-ẹrọ (gẹgẹbi awọn pilasitik imọ-ẹrọ ti a ṣe atunṣe, fikun ẹrọ pilasitik) ati ologbele-pari awọn ọja (gẹgẹ bi awọn paipu, awọn aṣọ-ikele, awọn okun). Akawe pẹlu nikan-dabaru extrusion ọna ẹrọ, Imọ-ẹrọ extrusion twin-screw ni awọn anfani ti agbara irẹrun ti o lagbara, ti o dara dapọ ipa, kongẹ otutu iṣakoso, kukuru ibugbe akoko ati ki o lagbara adaptability to aise ohun elo, eyiti o le yanju awọn iṣoro sisẹ ti awọn pilasitik ẹrọ ni imunadoko (gẹgẹ bi ifamọ si overheating ati hydrolytic ibaje, ko dara dapọ ipa, kekere processing ṣiṣe) ati rii daju didara awọn ọja ṣiṣu ẹrọ.
2.1 Ṣiṣe awọn iṣoro ti Awọn pilasitik Imọ-ẹrọ ati Awọn ibeere fun Ohun elo Extrusion
Bi darukọ sẹyìn, pilasitik ina- ni o tayọ okeerẹ išẹ, ṣugbọn iṣoro sisẹ wọn tun ga ju ti awọn pilasitik gbogbogbo lọ, nipataki nitori eto molikula pataki wọn ati awọn abuda iṣẹ. Awọn iṣoro sisẹ akọkọ ti awọn pilasitik ẹrọ ati awọn ibeere ti o baamu fun ohun elo extrusion jẹ atẹle:
2.1.1 Ifamọ si igbona pupọ ati ibajẹ Hydrolytic
Pupọ awọn pilasitik ina-ẹrọ (bii PA, PBT, PPS) jẹ ifarabalẹ si igbona pupọ ati ibajẹ hydrolytic. Ti iwọn otutu processing ba ga ju tabi akoko ibugbe ni extruder ti gun ju, pq molikula ti ṣiṣu ẹrọ yoo fọ, Abajade ni gbigbona ibajẹ, eyi ti yoo din awọn darí-ini, resistance ooru ati iṣẹ miiran ti ọja naa, ati paapa fa discoloration, carbonization ati awọn miiran abawọn. Ni afikun, diẹ ninu awọn pilasitik ina- (bii PA) ni gbigba omi ti o ga, 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: akọkọ, 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℃; keji, kukuru ibugbe akoko, 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 (nigbagbogbo 1-5 iseju) ati iṣakoso iwọn otutu deede, which are more suitable for engineering plastics processing than single-screw extruders (akoko ibugbe 5-10 iseju).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, erogba okun, talc, ina retardants, compatibilizers) to improve the performance of the product (such as reinforcing, toughening, ina retardant). Fun apere, 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. Ni afikun, the modular design of the twin-screw can freely combine different screw elements (such as conveying elements, dapọ eroja, shearing elements) 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.
This requires the screw and barrel of the extruder to be made of high-quality wear-resistant materials and processed by advanced manufacturing technology. Our HTS series extruders adopt imported wear-resistant alloy steel for the screw and barrel, and undergo bimetallic composite treatment or laser cladding treatment, which greatly improves the wear resistance and corrosion resistance of the screw and barrel, and can adapt to the processing of reinforced engineering plastics with high hardness modifiers.
2.1.4 High Requirements on Processing Fluidity and Pressure Control
Some engineering plastics (such as PPS, WO) 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; ni akoko kan naa, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, eyiti o jẹ pẹlu ibaraenisepo ti awọn ifosiwewe pupọ gẹgẹbi iwọn otutu, titẹ, rirun agbara ati akoko. 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, paipu, awọn aṣọ-ikele, awọn okun) through the die head. Ilana iṣẹ pato ati ṣiṣan ilana jẹ bi atẹle:
2.2.1 Aise Ohun elo 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 (bii PA, PC, POM), modifiers (such as glass fiber, erogba okun, talc, ina retardants), compatibilizers, lubricants and other additives. The pretreatment steps are as follows:
- Drying Treatment: Pupọ awọn pilasitik ina-ẹrọ (bii PA, PBT, PPS) ni gbigba omi ti o ga, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, dojuijako, reduced mechanical properties). Nitorina, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of engineering plastic: fun apere, PA6 is dried at 80-100℃ for 4-6 wakati, PA66 is dried at 100-120℃ for 6-8 wakati, PBT is dried at 120-140℃ for 2-4 wakati, PPS is dried at 150-160℃ for 3-5 wakati. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: According to the formula 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. The mixing speed is generally 800-1200 rpm, and the mixing time is 5-10 iseju. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (such as glass fiber), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 apapo.
2.2.2 Ono ati Gbigbe
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. Ẹrọ ifunni ti extruder nigbagbogbo ni ipese pẹlu iṣẹ ṣiṣe ilana iyara iyipada igbohunsafẹfẹ, which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding. The feeding hopper is also equipped with a drying device to prevent the raw materials from absorbing moisture again during feeding.
2.2.3 Yiyọ, Mixing and Shearing
Awọn ohun elo ti nwọle iho extrusion ti twin-skru extruder ti wa ni titari siwaju nigbagbogbo nipasẹ awọn skru yiyi. Iho extrusion ti wa ni kq ti a dabaru ati ki o kan agba, ati awọn iwọn didun ti awọn extrusion iho maa dinku pẹlú awọn axis itọsọna. Nigbati awọn skru yiyi, awọn ohun elo ti wa ni maa fisinuirindigbindigbin labẹ awọn iṣẹ ti awọn skru ati awọn agba, ati awọn titẹ ni extrusion iho maa posi (generally 5-15MPa).
Ni akoko kan naa, Awọn ohun elo naa wa labẹ agbara rirẹ ti o lagbara ati agbara ija ti ipilẹṣẹ nipasẹ iṣipopada ibatan laarin awọn skru ati agba, bi daradara bi laarin awọn dabaru ofurufu. 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. Agbara edekoyede tun le ṣe ina iwọn ooru kan, eyi ti o ti wa ni idapo pelu awọn ita alapapo ti awọn agba (itanna alapapo tabi nya alapapo) to make the engineering plastic resin gradually melt and plasticize.
Awọn agba ti extruder ti wa ni maa pin si 4-6 awọn apakan iṣakoso iwọn otutu (ono apakan, yo apakan, dapọ apakan, homogenizing apakan, kú ori apakan), and the temperature of each section is precisely controlled according to the type of engineering plastic. Fun apere, 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
The fully melted, mixed and dispersed material is pushed to the die head of the extruder by the screws. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (granules), 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, awọn aṣọ-ikele, awọn okun, 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, paipu, awọn aṣọ-ikele). The temperature of the die head is slightly lower than that of the homogenizing section, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, ati awọn itutu akoko ni 2-5 iseju; 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
After cooling and 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 (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 (awọn patiku iwọn ni gbogbo 2-5mm, eyi ti o le wa ni titunse gẹgẹ onibara aini). 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.
Ni afikun, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (bii ti o tobi ju, ju kekere tabi agglomerated patikulu); the inspection step is to detect the performance (such as mechanical strength, ooru resistance, onisẹpo yiye) 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, o kun pẹlu aise awọn ohun elo abuda, formula ratio, premixing effect, extrusion sile ki o si kú ori be. 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 Awọn abuda Ohun elo Raw
Iru, patiku iwọn, moisture content and purity of raw materials have a great impact on the extrusion effect. Fun apere, 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%; if the moisture content is too high, it will cause hydrolytic degradation of the material and bubbles in the product. Mimo ti awọn ohun elo aise tun ṣe pataki pupọ; impurities ni aise ohun elo (such as metals, stones, eruku) will not only affect the product quality, sugbon tun wọ dabaru ati agba ti extruder, ati paapaa fa idinamọ ẹrọ.
2.3.2 Ilana agbekalẹ
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. Fun apere, fifi 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. The type and dosage of additives also need to be reasonably matched: 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, mu 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 Effect
Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. If the premixing is uneven, 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. Lati rii daju awọn premixing ipa, o jẹ pataki lati šakoso awọn dapọ iyara, dapọ akoko ati dapọ otutu: awọn dapọ iyara ni 800-1200 rpm, awọn dapọ akoko ni 5-10 iseju, ati awọn dapọ otutu ti wa ni dari ni 40-60 ℃ (iwọn otutu ti o yẹ le mu imudara ti awọn afikun pọ si ati igbelaruge idapọ aṣọ).
2.3.4 Extrusion paramita
Awọn paramita extrusion jẹ awọn ifosiwewe pataki julọ ti o ni ipa ipa extrusion, o kun pẹlu dabaru iyara, extrusion otutu ati extrusion titẹ.
- Iyara dabaru: Awọn dabaru iyara ti ibeji-skru extruders fun ina- pilasitik gbogbo awọn sakani lati 100 si 1000 rpm. Wa HTS jara extruders le de ọdọ kan ti o pọju iyara ti 1000 rpm. Awọn ti o ga ni dabaru iyara, ti o pọju agbara irẹwẹsi ati agbara ija ti a gba nipasẹ awọn ohun elo, awọn dara dapọ ati dispersing ipa ti modifiers, ati awọn ti o ga gbóògì ṣiṣe. Sibẹsibẹ, ti o ba ti dabaru iyara jẹ ga ju, akoko ibugbe ti awọn ohun elo ti o wa ninu iho extrusion jẹ kukuru pupọ, Abajade ni aipe yo ti awọn resini, insufficient dapọ ti awọn ohun elo, ati uneven ọja didara; ti o ba ti dabaru iyara jẹ ju kekere, agbara rirun ati ija ija ko to, the modifiers cannot be fully dispersed, and the production efficiency is low. 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, WO), 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 otutu: 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. Iwọn otutu ti apakan ifunni jẹ kekere (slightly higher than the drying temperature of the raw materials), which is mainly to prevent the materials from caking and ensure smooth feeding; iwọn otutu ti apakan yo jẹ alabọde, which is mainly to promote the melting and plasticization of the resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of modifiers; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, 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 Ipa: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. Awọn titẹ ninu awọn extrusion iho wa ni o kun nipasẹ awọn funmorawon ipin ti awọn dabaru, awọn kú iho iwọn ati ki o dabaru iyara. Awọn ti o ga awọn extrusion titẹ, the better the mixing and dispersing effect of materials, and the denser the product. Sibẹsibẹ, if the pressure is too high, yoo mu agbara agbara ati yiya ti ẹrọ naa pọ si, and even cause the die head to block; ti o ba ti awọn titẹ jẹ ju kekere, the materials cannot be fully compressed and mixed, the product is loose, and the performance is unstable. The extrusion pressure should be adjusted according to the type of engineering plastic and the shape of the product: for high-viscosity materials and products with small die holes, a higher extrusion pressure is needed.
2.3.5 Kú Head Be
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
A ti gun a ti npe ni iwadi, development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, ga iki) 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, Ṣiṣe iṣelọpọ giga
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 jara ati HTS SUPER jara) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, which is much higher than that of ordinary twin-screw extruders (general torque is 8-12Nm/cm³). The high torque design ensures that the extruder can stably convey high-viscosity engineering plastic materials, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
Ni akoko kan naa, 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. Ni afikun, the high speed design also greatly improves the production efficiency: akawe pẹlu arinrin 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 iseju, which is much shorter than that of ordinary twin-screw extruders (5-10 iseju) and single-screw extruders (10-15 iseju). 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.
Ni afikun, 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 Iṣakoso iwọn otutu deede, Stable Performance
The HTS series extruders adopt an advanced intelligent temperature control system, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control precision can reach ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating and thermal decomposition of the material. The temperature control system is equipped with a real-time monitoring and alarm function: if the temperature of any section exceeds the set range, Eto naa yoo funni ni kiakia itaniji ni akoko, and even automatically adjust the heating power or shut down the equipment if necessary, lati yago fun ikuna ẹrọ ati awọn iṣoro didara ọja.
Ni afikun, the barrel of the HTS series extruders adopts a double-layer jacket design, which can realize rapid heating and cooling, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 O tayọ Dapọ ati Dispersing Ipa
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, pẹlu kan reasonable dabaru ipolowo, lead and compression ratio design. Ibaṣepọ ati yiyi ti awọn skru ibeji le ṣe ipilẹṣẹ agbara rirun ti o lagbara ati ipa ilọkun, which can fully break the agglomerates of modifiers (such as glass fiber, erogba okun, 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%, which is much higher than that of ordinary twin-screw extruders (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (such as conveying elements, dapọ eroja, shearing elements) can be freely combined according to the type of engineering plastic and modifier. Fun apere, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (such as PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 High Wear Resistance, Long Service Life
In 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 (such as 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) and ≥70 HRC (HTS PLUS jara ati HTS SUPER jara), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness modifiers. This greatly extends the service life of the screw and barrel: the service life of the screw and barrel of the HTS series extruders is 2-3 igba ti arinrin extruders, reducing the frequency of component replacement and the maintenance cost of the equipment.
Ni afikun, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, jade alaye yiya Iroyin, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.
3.1.6 Wide elo Ibiti, Strong Flexibility
The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (PA, PC, POM, PET, PBT) and special engineering plastics (PPS, WO, 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, ati be be lo.
The modular design of the HTS series extruders (dabaru, agba, kú orí, ati be be lo.) makes the replacement of components more convenient and quick. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, they only need to replace the corresponding components, lai a ropo gbogbo ẹrọ, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Ni afikun, the HTS series extruders can also be matched with different auxiliary equipment (gẹgẹbi awọn alapọpọ iyara-giga, agbẹgbẹ, coolers, granulators, screening machines, packaging machines) lati fẹlẹfẹlẹ kan ti pipe laifọwọyi gbóògì ila, realizing continuous production from raw material pretreatment to product packaging.
3.1.7 Intelligent Control, Easy Operation and Maintenance
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, eyi ti o rọrun ati ogbon inu, rọrun lati ṣiṣẹ. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, wọn nikan nilo lati pe agbekalẹ ti o baamu ati awọn paramita, lai tun ṣatunṣe, which saves time and improves production efficiency.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (such as temperature, titẹ, dabaru iyara, iyara ono) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, mimo ni oye gbóògì isakoso.
Ni afikun, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. Awọn dabaru, agba, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Wa lẹhin-tita iṣẹ egbe yoo pese ọjọgbọn fifi sori, Ifiranṣẹ ati awọn iṣẹ ikẹkọ fun awọn onibara, aridaju wipe awọn onibara le lo awọn ẹrọ laisiyonu.
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 jara ati HTS SUPER jara. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.
3.2.1 HTS Ipilẹ 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. Yi jara ti extruders nlo alabọde-torque gearboxes lati asiwaju European awọn olupese, eyiti o ni awọn anfani ti iṣẹ iduroṣinṣin, kekere ariwo, ga ṣiṣe ati ki o gun iṣẹ aye. The medium-torque design (iyipo pato 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, PET, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
Ni awọn ofin ti apẹrẹ igbekale, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, pẹlu kan dabaru opin orisirisi lati 30mm to 65mm, ati ipin funmorawon ti 4 ~ 8, which can be adjusted according to the type of engineering plastic. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. Extruder ti ni ipese pẹlu eto iṣakoso PLC ati wiwo iṣẹ iboju ifọwọkan, which can realize automatic feeding, laifọwọyi otutu iṣakoso, iṣakoso titẹ laifọwọyi ati gige gige laifọwọyi, and is simple and easy to operate.
The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, which is suitable for medium and small-sized engineering plastics processing enterprises that mainly produce general engineering plastics and low-to-medium modified engineering plastics. One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, kú ori, ono awọn ẹrọ, drying devices and post-processing equipment according to their own product types, gbóògì agbara ati isuna, ki o le fẹlẹfẹlẹ kan ti gbóògì ila dara fun ara wọn aini. The HTS BASIC series extruders have a reasonable price, eyiti o le ṣe iranlọwọ fun awọn ile-iṣẹ lati dinku idiyele idoko-owo akọkọ.
3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastics and Modified Products
The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, with a specific torque of 14Nm/cm³, which has stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
Awọn extruders jara HTS PLUS ni iwọn ila opin kan ti o wa lati 65mm si 110mm, ipin funmorawon ti 5 ~ 10, and a screw speed range of 200～800 rpm. Dabaru ati agba gba itọju akojọpọ bimetallic, eyi ti o ni ti o ga yiya resistance ati ipata resistance (líle dada ≥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, eyiti o le mọ iṣakoso kongẹ ti awọn aye imukuro ati ibojuwo akoko gidi ti data iṣelọpọ, 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 (bii PEEK, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, high performance and intelligence.
The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～1000 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, which has extremely high wear resistance and corrosion resistance (líle dada ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. The extruder is equipped with an intelligent PLC + cloud touch screen control system, which can realize remote parameter adjustment, gbóògì data monitoring, predictive maintenance of equipment and data analysis, mimo ni oye gbóògì isakoso.
The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, lagbara isọdi, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 iseju) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Ni afikun, 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, Awọn ile-iṣẹ nilo lati ṣe akiyesi ni kikun awọn iwulo iṣelọpọ tiwọn, ọja orisi, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. Awọn atẹle jẹ diẹ ninu awọn imọran yiyan pato:
3.3.1 Determine the Extruder Series According to the Type of Engineering Plastics
Different types of engineering plastics have different processing requirements, which determine the selection of extruder series. For general engineering plastics (PA6, PA66, POM, PET, PBT) with low modification degree (filling amount ≤30%), the HTS BASIC series is sufficient to meet the processing needs. Its medium torque and flexible configuration can balance processing effect and cost, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (filling amount 30%-50%, such as glass fiber reinforced PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (such as PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (WO, 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; fun o tobi-asekale gbóògì (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 (gẹgẹ bi awọn ina retardants, compatibilizers, reinforcing agents) ni akoko kan naa, 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. Fun apere, 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. Ni afikun, 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. Ni afikun, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, pẹlu fifi sori, ifiṣẹṣẹ, ikẹkọ imọ-ẹrọ, 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, ga-iyara aladapo, cooler, granulator, screening machine, packaging machine, ati be be lo. 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. Fun apere, 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
Awọn pilasitik ẹrọ, with their excellent comprehensive performance, have been widely used in automotive, itanna ati itanna, oogun, ofurufu, kemikali, 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. Ni isalẹ, 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: Ìwúwo Fúyẹ́, 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, ati be be lo., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: fẹẹrẹfẹ, high temperature resistance, wọ resistance, dimensional stability and low VOC (iyipada Organic agbo), 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, enu paneli, 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 (WO, 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.
Ikẹkọ Ọran: 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 iseju) 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% si 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, onirin lọọgan, relays, awọn mọto, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, idaduro ina, onisẹpo iduroṣinṣin, 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, awọn asopọ) 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, WO, PSU, ati be be lo., which are mainly used in medical containers, egbogi catheters, medical implants, surgical instruments and other products. The core requirements for extrusion processing are: ga konge, no pollution, idurosinsin išẹ, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (gẹgẹbi awọn apoti iwosan, 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 (medical-grade 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 (Ti o dara Manufacturing Àṣà) 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, ati be be lo., 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, idurosinsin išẹ, 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, eyi ti o le orisirisi si si awọn processing ti ga-lile modifiers (gẹgẹ bi awọn erogba okun, seramiki okun); PLC ti o ni oye + Eto iṣakoso iboju ifọwọkan awọsanma le mọ iṣakoso kongẹ ti awọn paramita extrusion, ati ibojuwo latọna jijin ati iṣẹ itọju asọtẹlẹ le rii daju iṣẹ iduroṣinṣin ti ẹrọ ni iṣelọpọ ilọsiwaju igba pipẹ; iṣeto ni asefara le pade awọn iwulo sisẹ pataki ti ọpọlọpọ awọn paati aerospace, aridaju iṣẹ giga ati igbẹkẹle giga ti ọja naa.
4.5 Aaye Kemikali: Ipata Resistance ati Wọ Resistance
Aaye kemikali ni agbegbe iṣẹ lile, ati awọn pilasitik ti imọ-ẹrọ ti a lo ninu aaye kemikali gbọdọ ni resistance ipata to dara julọ, wọ resistance, ga otutu resistance ati titẹ resistance. Awọn pilasitik imọ-ẹrọ akọkọ ti a lo ninu aaye kemikali pẹlu PPS, WO, PVDF (polyvinylidene fluoride), ati be be lo., which are mainly used in chemical equipment, pipelines, falifu, pumps and other products. The core requirements for extrusion processing are: ipata resistance, wọ resistance, idurosinsin išẹ, 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 (WO, PI), the HTS SUPER series extruders are required. Its ultra-high torque and stable conveying capacity can cope with the high viscosity of high-end corrosion-resistant materials, and the laser-clad screw and barrel have extremely high corrosion resistance and wear resistance, which can meet the long-term use requirements in harsh chemical environments; the precise temperature control can avoid thermal decomposition of materials, ensuring the corrosion resistance and pressure resistance of the product.
5. Common Problems and Solutions in Engineering Plastics Twin-Screw Extrusion Processing
In the actual twin-screw extrusion processing of engineering plastics, due to the influence of raw materials, processing sile, equipment performance and other factors, orisirisi isoro igba waye, which affect the product quality and production efficiency. Ni isalẹ, 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 Isoro 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, awọn nyoju, 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.
Awọn okunfa: 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.
Awọn ojutu: 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 (iwọn otutu iṣakoso konge ± 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 iseju; 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 Isoro 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (such as glass fiber, erogba okun), and the mechanical properties (agbara, lile, wọ resistance) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Awọn okunfa: 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.
Awọn ojutu: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 iseju), 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 apapo) and meets the processing requirements.
5.3 Isoro 3: Wear of Screw and Barrel
Symptoms: After a period of use, the extrusion capacity of the extruder decreases, the shear force and mixing effect are reduced, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (such as glass fiber, erogba okun) on the screw and barrel during the processing of reinforced engineering plastics.
Awọn okunfa: 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.
Awọn ojutu: 1. Select extruders with high wear resistance, such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS Plus) and ≥70 HRC (HTS SUPER), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, and apply lubricating oil appropriately to reduce friction and extend the service life. Ni afikun, our professional technical team can provide regular wear detection services for the screw and barrel, and put forward targeted replacement and maintenance suggestions.
5.4 Isoro 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, paipu, awọn aṣọ-ikele) 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.
Awọn okunfa: 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.
Awọn ojutu: 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 iseju) 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 Isoro 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.
Awọn okunfa: 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.
Awọn ojutu: 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. Ni afikun, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% akawe pẹlu arinrin extruders.
6. Conclusion and Future Development Trend
Awọn pilasitik ẹrọ, bi bọtini iṣẹ ṣiṣe giga, 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, ṣiṣe iṣelọpọ ati ipa ohun elo ti awọn ọja ṣiṣu ẹrọ. Our HTS series twin-screw extruders, pẹlu HTS Ipilẹ, 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, ga iki), with the advantages of high torque, ere giga, kongẹ otutu iṣakoso, o tayọ yiya resistance, 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, itanna ati itanna itetisi, 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:
Ni akọkọ, 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. Ni akoko kan naa, 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.
Keji, high performance and high efficiency. The demand for high-end engineering plastics (bii 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 (dabaru, agba, apoti jia) will be further optimized to improve wear resistance, corrosion resistance and service life. Ni akoko kan naa, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Kẹta, 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. Ni akoko kan naa, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Ẹkẹrin, 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; ni akoko kan naa, 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.