Classification of solidification processes. Principle of the process Structure/Configuration Process...
-
Upload
mae-carpenter -
Category
Documents
-
view
242 -
download
1
Transcript of Classification of solidification processes. Principle of the process Structure/Configuration Process...
![Page 1: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/1.jpg)
Classification of solidification processes
![Page 2: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/2.jpg)
Principle of the process
Structure/Configuration
Process modeling
Defects/quality control
Design For Manufacturing (DFM)
Process variation2
![Page 3: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/3.jpg)
Shaping Processes For Plastics - Extrusion
1. Introduction
Screen pack
3
![Page 4: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/4.jpg)
1. Introduction
Extrusion is a process in which
the material is forced to flow through a die
orifice to provide a long, continuous product
whose cross-sectional shape is determined by
the shape of the orifice
4
Shaping Processes For Plastics - Extrusion
![Page 5: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/5.jpg)
2. Analysis of Flow Rate
5
Shaping Processes For Plastics - Extrusion
![Page 6: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/6.jpg)
Find the flow rate with respect to various parameters in the system. These parameters include: parameters of the screw, the clearance between the screw and the inner surface of the barrel.
6
Shaping Processes For Plastics - Extrusion
![Page 7: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/7.jpg)
The goal of the engineering analysis:
7
1. The flow rate or production rate.
2. The pressure of the or product
![Page 8: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/8.jpg)
1. Flow rate inside the extruder and at the die ?
2. Flow rate outside the extruder and at the die ?
dieThe balance between the two should lead to the flow rate as well as pressure
8
Extruder
The general idea to meet the goal:
![Page 9: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/9.jpg)
Flow rate of the extruder (not including the die)
Drag flow
Barrel
Screw surface
d
w
v
9
![Page 10: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/10.jpg)
vdwQd 5.0
ADNv cos
AANdDQ cd cossin5.0 22 (1)
dc
tan cosc fw D A A w
10
![Page 11: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/11.jpg)
tan cosc fw D A A w
11
![Page 12: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/12.jpg)
)(12
sin23
dl
dpADdQ cb
Back pressure flow
12
![Page 13: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/13.jpg)
)(12
sin23
dl
dpADdQ cb
Back pressure flow
L
ADdpQ cb
12
sin 23
(2)
13
![Page 14: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/14.jpg)
Net forward flow Qx
L
ADdpAANdDQ c
cx
12
sincossin5.0
2322
(3)
14
Linear relation between the net flow rate and head pressure.
Assumption: viscosity is constant.
The structure: extruder only not including die.
![Page 15: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/15.jpg)
L
ADdpAANdDQ c
cx
12
sincossin5.0
2322
The design parameters: those that define the geometry of the screw and barrel.
The operating parameter: those that can be changed during the process to affect the output flow
Variable15
Shaping Processes For Plastics - Extrusion
![Page 16: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/16.jpg)
Maximum pressure and maximum net flow rate
L
ADdpAANdDQ c
c
12
sincossin5.0
2322
max
0
Maximum head pressure to cause no flow
2max
cot6
cd
ADNLp
16
Shaping Processes For Plastics - Extrusion
![Page 17: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/17.jpg)
pmax
Qmax
Extruder characteristic
p
Q
17
Shaping Processes For Plastics - Extrusion
![Page 18: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/18.jpg)
Determination of the operating point
Pressure and Flow rate
diepKQ sx
d
ds L
DK
128
4
Die characteristic
18
Shaping Processes For Plastics - Extrusion
![Page 19: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/19.jpg)
Determination of the operating point
p
Qmax
pmax
Operating point
Die characteristic
Extruder characteristic
Qx
19
Shaping Processes For Plastics - Extrusion
![Page 20: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/20.jpg)
Example:
Given: diameter D=120 mm
length =3.0 m
channel depth =8.0 mm
pitch = 95 mm
viscosity = 75 pas
head pressure = 4.0 Mpa
Find: the rotational speed of the screw required to
achieve a volumetric flow rate of 90 cm3/s
20
![Page 21: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/21.jpg)
Solution to be filled in the classroom
21
![Page 22: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/22.jpg)
Discussion
22
Shaping Processes For Plastics - Extrusion
A manufacturing process is to the material to meet requirements.
Requirements: quality, quantity, time, cost, green and sustainability.
Quantity with respect to time is called production rate.
The whole manufacturing system at the equipment level can be viewed as consisting of devices and materials.
![Page 23: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/23.jpg)
Discussion
23
Shaping Processes For Plastics - Extrusion
Both the device and material are under the manipulation from the external system that supplies energy or power and material.
There are several parameters and variables in the manufacturing system: device parameter, process parameter, product parameter.
![Page 24: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/24.jpg)
Discussion
24
Shaping Processes For Plastics - Extrusion
Device parameter also system or design parameter: the one category of parameters that describe the device, e.g., the diameter of the extruder, length of the extruder, etc.
Process parameter also operating parameter: the one category of parameters that describe the process on the material, e.g., the rotational speed of the screw bar, heat energy supply, material supply rate, etc.
Product parameter: the one category of parameters that describe or characterize the product which is the output from a manufacturing system, e.g., the flow rate, etc.
![Page 25: Classification of solidification processes. Principle of the process Structure/Configuration Process modeling Defects/quality control Design For Manufacturing.](https://reader035.fdocuments.us/reader035/viewer/2022062715/56649d6f5503460f94a5187a/html5/thumbnails/25.jpg)
Discussion
25
Shaping Processes For Plastics - Extrusion
Manufacturing system design and control:
1. Device design: to determine the device parameter.
2. Process design: to determine the process configuration and
parameter.
3. Product modification: design for process.
4. Device control.
5. Process control.
Product quality, quantity, cost, time, green and sustainability