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How to solve the six major problems encountered in plastic processing?
The six major problems encountered in plastic processing are as follows:
1. Analysis of the reasons for the excessive black points
The quality of the raw materials itself is poor, and the black spots are excessive;
Local overheating of the screw causes the material to become carbonized, and the char is brought into the strip, causing more points;
The local shear of the screw is too strong, causing the material to become carbonized, and the char is brought into the strip, causing more points;
The pressure of the machine head is too large (including blockage, too much filter screen, too low temperature of the machine head, etc.), too much reflow material, carbonization of the material is increased, and charcoal is brought into the material strip, causing more points;
The service life of the machine is too long, the gap between the screw and the barrel increases, and the adhesion of the wall of the barrel increases. As the extrusion time passes, it is gradually brought into the material strip, causing more points.
The natural exhaust port and the vacuum exhaust port are not cleaned for a long time, and the accumulated carbonized material is increased, and the continuous extrusion is carried into the strip in the subsequent period, resulting in a larger number of points;
The external environment or artificially caused other impurities to mix in, resulting in more black spots;
The die (including the discharge port and the internal dead angle) is not cleaned, resulting in more black spots;
The discharge port is not smooth enough (for example, some shallow grooves and potholes, etc.), and materials may accumulate for a long time. As the extrusion time elapses, it is gradually carbonized and then carried into the material strip, causing more black spots;
Part of the thread original damage (corner angle, wear, etc. form a dead angle), resulting in carbonization of the material at the dead corner, in the subsequent continuous extrusion process, is gradually brought out to the strip, resulting in more black spots;
Natural exhaust and vacuum exhaust are not smooth, causing carbonization of the material in the screw, resulting in more black spots.
2, analysis of the processing of finished products
Broken bars produce the original deficiency:
Increase the mesh number or the number of sheets;
Appropriately reduce the host speed or increase the feed speed;
Properly reduce the extrusion processing temperature (head or other zones).
External impurities:
Check whether the dead angle of equipment in all aspects of mixing and discharging is cleaned up and impurities are mixed in;
Minimize the addition of broken material or artificially screen the broken material to remove impurities;
Increase the number of mesh screens and the number of sheets;
Try to cover the holes (solid covers or net covers) that may have fallen debris.
Internal impurities:
The head pressure is too high (including the blockage of the die, too much filter, the temperature of the head is too low, etc.), causing the increase of the reflux to cause the carbonization to increase, and the char is taken out to the strip, causing a broken strip under the traction force;
The extruder is partially overheated, causing the carbonization to increase, and the char is taken out to the strip, causing a broken strip under the traction force;
The shearing of the screw is too strong, causing the local carbonization of the material to be aggravated, and the char is taken out to the strip, causing a broken strip under the action of traction;
The machine has a long service life, the screw and the barrel are worn, the gap is increased, the backflow is increased, and the carbon carbide adhering to the barrel wall is increased. As the extrusion time is extended, the char is gradually taken out to the strip, causing a broken strip under the traction force. ;
Vacuum or natural vents (including gaskets and dead ends) are not cleaned for a long time, and the existing char is brought to the strip, causing broken strips under the action of traction;
The die of the machine head (including the discharge port and the internal dead angle of the machine head) is not cleaned, and the die contains carbonized material or impurities and is brought to the strip, which causes a broken strip under the traction force;
The time interval for replacing the filter is too long, the filter screen is blocked, and the material does not come out, causing broken bars.
Poor plasticization of materials:
The extrusion temperature is too low or the screw shear is too weak, the material is not fully plasticized, and the material is smashed, causing a broken strip under the action of traction;
Low-melting-point auxiliaries (including EBS or PETS, etc.) in the formulation system cause poor plasticization and broken strips under the premise that the screw shear is weak or the gap between the screw and the barrel is increased and the shear is weak.
Material properties change:
The blending components are too different at the same temperature, and the fluidity is not matched or not fully compatible (including physical entanglement and chemical reaction). Theoretically, this is called "phase separation" and "phase separation". Generally, blending extrusion does not occur, and it occurs more frequently in the injection molding process. However, if the MFR difference is too large, a broken strip may occur under the premise that the screw is relatively weakly sheared;
The viscosity of the blended components changes:
For the same material, if the MFR is reduced, the hardness, rigidity and notch become larger, it is possible that the molecular weight of the batch is larger than before, resulting in a large viscosity, which causes plasticity under the original processing temperature and process. Poor aging, at this time to increase the extrusion temperature or reduce the screw speed of the main machine can be solved.
The strip is trapped or exhausted:
The processing temperature is too high or the local shear of the screw is too strong or the screw is partially overheated, causing the decomposition of some flame retardants and other additives, releasing the gas, the vacuum does not extract the gas in time, the gas is trapped inside the strip, under the traction force Causing a broken strip;
The material is seriously damp, the processed water vapor is not removed by natural exhaust and vacuum in time, and the steam trap is trapped in the strip, which causes a broken strip under the action of traction;
Natural exhaust or vacuum exhaust is not smooth (including blockage, air leak, gasket is too high, etc.), causing gas (or steam) trapped in the strip, under the action of traction, causing broken strips.
The material is too rigid, the water is too cold or too much water, and the traction does not match:
The material is too rigid, the water temperature is too low, too much water, the discharge of the machine head is very soft, and the water immediately becomes very hard. Under the effect of mismatching traction, the broken strip is caused. This phenomenon often occurs in PBT or PET fiber, PC fiber, AS fiber, ABS fiber and other materials with very fast crystallization speed or very high rigidity, especially for small machines, the experiment is more serious. At this time, increase the water temperature, reduce the water volume, and let the cut The strip of the granulator keeps a certain degree of softness and can be solved.
The filter mesh is too low or the number of sheets is not enough:
This phenomenon often occurs when the above-mentioned machine head is under pressure, external impurities and internal impurities.
3. Analysis of granulation hollow problem
Poor exhaust:
Exhaust (or steam) is not smooth: due to natural exhaust or vacuum exhaust (may be too heavy in the material itself, it may also be decomposed by additives such as flame retardants, there may be vacuum blockage or vacuum is too small or leaking or The vacuum gasket is too high, etc., causing a gas (vapor) body to form a hollow.
Poor plasticization:
The processing temperature is low, the material is not completely plasticized, the light (small hole) causes the particles to be hollow, and the heavy one (large hole) causes the broken strip;
There are too many low-melting auxiliaries (including EBS or PETS), and the shearing of the screw is weak (for example, the production of ordinary ABS on the 2nd line, the EBS cannot be too much, and too many "pores" appear), resulting in poor plasticization of materials. Forming a hollow;
There are too many low-melting auxiliaries (including EBS or PETS), and the gap between the screw and the barrel is increased (for example, ordinary wire ABS is produced on line 1, sometimes EBS is not too much, too many "pores" appear) or screw shear Under the premise of weaker conditions, plasticization is poor and hollowness is formed.
The water temperature is too low, the cooling water temperature is too low, and the material shrinks with water, causing shrinkage holes, such as PP products - such phenomena are mainly for crystalline plastics; in general, crystalline plastics (such as PP, PA, PBT, etc.) Low water temperature should be used, and non-crystalline plastics (such as ABS, PC/ABS, HIPS, etc.) use high water temperature.
4, natural exhaust port, vacuum material
Natural vents:
The feed speed does not match the host speed, and the feed speed is appropriately reduced or the host speed is increased;
The temperature in the region from the feeding section to the natural exhaust port is too low, the material is not plasticized, and under the action of the screw extrusion, the raw material is generated;
The temperature near the natural exhaust port is too high, the viscosity of the material is seriously degraded, the screw is slipped in this section, and the material cannot be transported to the front section in time, and the clinker is caused by the subsequent crushing of the flow;
The position of the natural exhaust port of the screw does not match the position of the natural exhaust port of the barrel, resulting in a raw material;
There is no reverse conveying element or reverse meshing block here, which can not reduce the pressure of the natural exhaust port groove, which will cause the material to flow under the subsequent crushing action.
Vacuum material:
The vacuum pumping force is too large, and the material is sucked into the vacuum pipe to cause the raw material;
The screw vacuum position is not provided with the reverse conveying element or the reverse meshing block, and the pressure of the vacuum section screw groove cannot be reduced, and the vacuum is caused by the vacuuming;
The temperature of the vacuum section is too high, the viscosity of the material is seriously degraded, the screw of this section is slippery, the material cannot be transported to the front section in time, and under the action of vacuum pumping, the raw material is caused;
The extrusion processing temperature is too low, the material is not plasticized or the flame retardant and the like are not sufficiently dispersed in the resin, and under the action of vacuum pumping, the raw material is caused;
The screw combination is also reasonable, the position is also matched, the temperature and the main machine and the feeding speed are also matched, the vacuum gasket is low, and the material is caused by the material extrusion and the vacuum pumping force;
The pressure on the machine head is too large (the reasons include: blockage of the die, too much filter net, too low temperature of the machine head, etc.), causing an increase in the backflow, causing a flue under the action of vacuum pumping.
5, hopper bridge
Too much filler, moisture absorption, agglomeration, resulting in increased friction between the mixture and the hopper wall, adding liquid lubricants such as “white oil†to reduce the friction between the mixture and the hopper wall and the mixture, which can be solved;
Mixture agglomeration (including high temperature agglomeration and liquid additives added too much to agglomerate), reduce drying temperature or high mixing time, reduce the amount of liquid additives added, add powdery resin that absorbs "oily" substances Or additives (such as high rubber powder, AS powder, PP powder, etc.) can be solved.
6, the laying bridge
Mainly because the melting point of some processing aids is too low, the processing temperature of one zone and two zones is too high, the material softens in the feeding silo, and adheres to the equipment wall, which makes the subsequent material feeding difficult, and appropriately reduces the processing of one zone and two zones. Temperature can be solved.