Extrusion Processes

Extrusion of plastics, like injection molding, is a

relatively simple concept, but the design and
application of extruders is a complex field

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 Melt Extrusion, Single Screw Extruders

The work horse of melt extrusion is the single

screw extruder

In injection molding the purpose
of the screw extruder is simply
to obtain a melt, a dedicated
extrusion machine works on the
same principle but also must
mix, homogenize and melt the
material

Higher back pressures may be
generated in single screw
extrusion machines compared to
injection molding machines and
the screws may be longer for
better mixing

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 Single Screw Extruder
(Plastics Extrusion Technology, 2nd ed pg 23)

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 The Extrusion Screw
In combination with the barrel, the purpose of the screw is
to convey solid material to the melt zone, melt, mix and
pump material to the die in an efficient manner

The screw design and length of screw will depend on the polymer
being processed as well as the application

Text pg 169

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 Melt Considerations in Extrusion Screws

Increasing the capacity by “pumping” more material

through the screw can be done by increasing the length of
the screw and or flight dept, but this only helps to a point
For hard to melt materials or to increase melt homogeneity,
a second or third flight may be added to a screw in order to
prevent unmelted material from reaching the die

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 Mixing Considerations in Extrusion Screws

While melting and “pumping” as much polymer to

the die as possible is important, mixing material in
compounding applications is equally important;
there are many ways of achieving good mixing

Pins may be placed in strategic placed in the metering
section of a screw

Fluted sections at the end of the screw help to both mix
and melt left over solid polymer

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 Pin Arrangements and Fluted Sections

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 Twin Screw Extruders
Twin screw extruders are used to process heat sensitive
and shear sensitive materials and may provide intensive
mixing by kneading

PVC is the highest volume material processed by twin screw extruders

There are two types of screw extruders, co-rotating and

counter-rotating screw extruders

The screws in co-rotating extruders turn in the same direction

The screws in counter rotating extruders turn in opposite directions

For either class of extruder, the flights may or may not be

intermeshing

Intermeshing extruders work on a different principle than single screw
extruders; material is “pumped” by forward action of the root of one screw
against the flights of the other

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 Twin Screw Extruder Melt Flow
Co-rotating intermeshing extruders are the most common
twin screw extruder type

In this case the root of one screw is wiped by the crests of the adjacent
screw flights

The material follows a figure 8 patterns

Residence time is short and shearing is low

Provides very accurate process control
Counter rotating intermeshing extruders are the next most
common type

Material in this case is moved as a unit volume between the screws
and barrel

Spacers, disk rings and other flow interrupters may be used to
disrupt the characteristic encapsulated flow

Higher material volumes may be extruded in this configuration

This type of extruder evolved from pumping machines

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 Material Flow Around Twin Screws

Plastic extrusion
technology handbook pg57

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 Die Swell
When polymer exits the die of the extruder it will swell,
this action is referred to as die swell

Die swell occurs because the sudden release of pressure causes the polymer
chains to relax; remember, polymers are viscoelastic and display time
dependent stress relaxation

Go to http://www.pct.edu/prep/ex.htm and click on the die swell animation
to view a cartoon of the concept
High shear rates (and thus compression at the die) followed by
sudden release of pressure is the main factor responsible for
die swell; shear rate and pressure can be influenced by…

Increasing the output rate

Decreasing die orifice dimension

Reducing the melt temperature

Increasing molar mass (molecular weight), chain branching

Decreasing the die L/D ratio

11
 Effects of Die Swell on Profile Shapes

Text pg 172

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 Post Forming of Profiles
To avoid the necessity of
having a complex die orifice for
complex shapes, post forming
may be accomplished on basic
shapes

This is essentially a
thermoforming process where
the still warm extrudate is
shaped and drawn through a
series of plates, shoes, rollers or
dies to form the final shape

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 Extrusion Shapes
For melt extrusion the extrusion machine will be similar
for all cases, the die and application being differentiating
facets
The shape of the extruded section will depend on the die
orifice shape (and die swell, of course); the type of shape
produced is divided into several categories

Sheet (more than 0.25 mm thick)

Film (less or equal to 0.25 mm thick)

Blown, film casting, calendering

Filament

Blow molding

Wire insulation

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 Sheet Extrusion

ASTM has defined sheet as being more than 0.25

mm thick
Sheet is extruded by cast extrusion, which simply
refers to sheets being extruded through a
horizontal die

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 T-Shaped Sheet Die

Plastics extrusion
technology handbook

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 Coat Hanger Sheet Die

Plastics extrusion
technology handbook

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 Cut Away Coat Hanger Sheet Die View
(Shown is a Flex-Lip® adjustable preland replacing the restrictor-bar)

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 Film Extrusion
ASTM has defined film as being equal to or less than 0.25
mm in thickness
Film can be extruded in a similar manner as sheet in a
process referred to as slot casting

In this case, the film is drawn from the die onto chilled rollers that quickly
quench the material
The blown film process extrudes a tube of material and
pinches of the end while simultaneously blowing the tube
into a thin walled “balloon”
Click on the download button at
http://www.glad.com.au/student_main.asp to get product
propaganda but also some interesting info. on how Glad
Wrap® and garbage bags are made at Glad
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 Blow Molding
The basic principle of blow molding is simple; a hollow molten
preform or tube is placed in a female mold and inflated to
conform to the shape of the mold

Two different varieties of blow molding

Injection blow molding – is a two step process where a blank
preform is first molded, it is then transferred to the mold cavity
where it is blown into shape

The advantages of injection molding are good control of
wall thickness, no bottom pinch off line, no scrap; the
main disadvantage is requiring two molds and transfer
time to the mold after performing

Extrusion blow molding – a molten tube (parison) is
extruded, without pre-forming, the bottom of the parison is
pinched of by the mold and air is used to blow it into shape

The main disadvantage of this method is the less
controllable wall thickness, though some basic control is
possible

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 Injection Blow Molding
parison

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 Extrusion Blow Molding
The wall thickness of
extruded parisons may be
controlled by the use of a
variable orifice die

This type of die can

continuously change the
orifice tube width and is
typically computer
controlled

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 Variations on Blow Molding
Injection and extrusion blow molding are the basic
methods by which blow molded products are made, there
are many variations on these concepts to make the process
faster, and more efficient

Merry go round like mold arrays may be used to continuously
mold without having to waiting for cooling before molding again

Multilayered containers can be made by co-extrusion

Used extensively in food storage containers, high strength bags

Sheet blow molding can be accomplished by heating two separate

sheets, clamping them together in a mold and blowing to shape

Different color sides can be produced but high scrap rates are
prevalent

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 Resources and References
As with injection molding there is a great quantity of literature on
extrusion and extrusion processes, following are just some references

Levy and Carley, eds.. Plastics Extrusion Technology Handbook, 2nd Ed.. New
York, First Printing, 1989.

Rosato, Domic and Donald, et al, eds.. Plastics Engineering Manufacturing and
Data Book, Vol. 1. Boston, Kluwer Academic Pub., 2001.

Birley, Arthur; Haworth, Barry; Batchelor, Jim. Physics of Plastics, Processing,
Properties and Materials Engineering. New York, Oxford Press, 1992. (Presents
more of a materials engineering view of processing)

SPE extrusion division on line at http://www.extdiv4spe.org/
The Plastics Resources for Educators Program.
http://www.pct.edu/prep/core.htm - great descriptions and animations of
processes. Review animations for extrusion and injection.

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