Design, Manufacturing, and Comparative Analysis of a Mini Extruder for Polymer Flow Characterization: A Case Study on HDPE and PMMA Polymers

Yıl 2024, Cilt: 12 Sayı: 2, 680 - 695, 29.04.2024

Emin Uslu , Galip Yılmaz

https://doi.org/10.29130/dubited.1272683

Öz

Polymer extrusion is one of the most widely used polymer processing methods and the sole option for many standard products. The modern extrusion machine has a very sophisticated design; for example, the extrusion screw has different zones and complex geometry. Determining the proper processing settings is always a challenge for engineers. Additionally, complex rheological properties of the polymers in extrusion sometimes yield challenging and unpredictable problems to troubleshoot. For convenience, a small-scale extrusion machine can be used to troubleshoot and analyze the polymers rather than the large manufacturing machines that are hard to work with. This study has produced a small-scale extrusion machine that is easy to manufacture without deviating from the extrusion process's nature. The extruder, whose production details are given, was tested with two different polymers: HDPE and PMMA. The correct temperature and screw rotation speed were determined with the extruder for the proper process parameters. In addition, the temperature-viscosity relationship of the polymers' flow nature was also determined.

Anahtar Kelimeler

On-site viscosity testing, Extrusion, Polymer processing, Equipment designing, HDPE, PMMA

Polimer Akış Karakterizasyonu için Bir Mini Ekstrüderin Tasarımı, Üretimi ve Karşılaştırmalı Analizi: HDPE ve PMMA Polimerleri Üzerine Bir Uygulama

Öz

Polimer ekstrüzyon, en yaygın kullanılan polimer işleme yöntemlerinden biridir ve birçok standart ürün için tek seçenektir. Modern ekstrüzyon makinesi çok karmaşık bir tasarıma sahiptir; örneğin ekstrüzyon vidasının farklı bölgeleri ve karmaşık geometrisi vardır. Doğru proses ayarlarını belirlemek, mühendisler için her zaman bir zorluk olmuştur. Ek olarak, polimerlerin karmaşık reolojik özellikleri bazen çözülmesi zor ve öngörülemeyen sorunlara yol açar. Kolaylık sağlamak için, çalışması zor olan büyük imalat makinelerinden ziyade polimerlerin sorunlarını gidermek ve analiz etmek için küçük ölçekli bir ekstrüzyon makinesi kullanılabilir. Bu çalışma kapsamında, ekstrüzyon işleminin doğasından sapmadan üretimi kolay, küçük ölçekli bir ekstrüzyon makinesi üretilmiştir. Üretim detayları verilen ekstrüder, HDPE ve PMMA olmak üzere iki farklı polimer ile test edilmiştir. Uygun proses parametreleri için ekstrüder ile doğru sıcaklık ve vida dönüş hızı belirlenmiştir. Ayrıca bu polimerlerin akış özelliklerinin tayini sıcaklık-viskozite ilişkisi belirlenmiştir.

Anahtar Kelimeler

Yerinde viskozite testi, Ekstrüzyon, Polimer işleme, Ekipman tasarımı, HDPE, PMMA

Kaynakça

• [1] M. Yousfi, C. Samuel, J. Soulestin, and M.-F.Lacrampe, "Rheological considerations in processing self-reinforced thermoplastic polymer nanocomposites: A review," Polymers, vol. 14, no. 3, pp. 637, 2022.
• [2] P. Jagadeesh, S. Mavinkere Rangappa, S. Siengchin, M. Puttegowda, S.M.K. Thiagamani, G. Rajeshkumar, M.H. Kumar, O.P. Oladijo, V. Fiore, and M.M.M. Cuadrado, "Sustainable recycling technologies for thermoplastic polymers and their composites: A review of the state of the art," Polymer Composites, vol. 43, no. 9, pp. 5831-62, 2022.
• [3] S. Boran Torun, M. Özdemir, E. Peşman, and A. Dönmez Çavdar, "Evaluation of vegetable waste oil and old newspaper fibers in waste polypropylene composites," Duzce University Journal of Science and Technology, vol. 11, no. 2, pp. 936–957, 2023.
• [4] H. Fu, H. Xu, Y. Liu, Z. Yang, S. Kormakov, D. Wu, and J. Sun, "Overview of injection molding technology for processing polymers and their composites." ES Materials & Manufacturing, vol. 8, no. 3, pp. 23, 2020.
• [5] C.E. Montilla-Buitrago, R.A. Gómez-López, J.F. Solanilla-Duque, L. Serna-Cock, and H.S.Villada-Castillo, "Effect of Plasticizers on properties, retrogradation, and processing of extrusion-obtained thermoplastic starch: A review," Starch - Stärke, vol. 73, pp. 2100060, 2021.
• [6] M. Hyvärinen, R. Jabeen, and T. Kärki, "The Modelling of extrusion processes for polymers—A review," Polymers, vol. 12, no. 6, pp. 1306, 2020.
• [7] V.J.R.R. Pita, E.E.M. Sampaio, and E.E.C Monteiro, "Mechanical properties evaluation of PVC/plasticizers and PVC/thermoplastic polyurethane blends from extrusion processing," Polymer Testing, vol. 21, no. 5, pp. 545-550, 2002.
• [8] H. Yin, X. Huang, T. Liu, and M. Song, "Effects of gas-assisted extrusion on slip in the cable coating process," Journal of Polymer Engineering, vol. 41, no. 4, pp. 329-337, 2021.
• [9] P. Poungthong, C. Kolitawong, and A.J. Giacomin, "Cooling and annealing of plastic pipe," Thermal Science and Engineering Progress, vol. 25, pp. 100970, 2021.
• [10] A.L. Kelly, E.C. Brown, and P.D. Coates, "The effect of screw geometry on melt temperature profile in single screw extrusion," Polymer Engineering & Science, vol. 46, no. 12, pp. 1706-1714, 2006.
• [11] J. Wang, "Influence of helical grooved structure on mixing process in a single screw extruder," Key Engineering Materials, vol. 561, pp. 212-217, 2013.
• [12] A. La Gala, R. Fiorio, M. Erkoç, L. Cardon, and D.R. D’hooge, "Theoretical evaluation of the melting efficiency for the single-screw micro-extrusion process: The case of 3D printing of ABS," Processes, vol. 8, no. 11, pp. 1522, 2020.
• [13] C. Capone, L. Di Landro, F. Inzoli, M. Penco, and L. Sartore, "Thermal and mechanical degradation during polymer extrusion processing," Polymer Engineering & Science, vol. 47 no. 11 pp. 1813-1819, 2007.
• [14] S.M. Alshahrani, J.T. Morott, A.S. Alshetaili, R.V. Tiwari, S. Majumdar, and M.A. Repka, "Influence of degassing on hot-melt extrusion process," European Journal of Pharmaceutical Sciences, vol. 80, pp.43-52, 2015
• [15] K.A. Crookston, T. Mark Young, D. Harper, and F.M. Guess, "Statistical reliability analyses of two wood plastic composite extrusion processes," Reliability Engineering & System Safety, vol. 96, no. 1, pp. 172-177, 2011.
• [16] G. Hsiang Loh, E. Pei, J. Gonzalez-Gutierrez, and M. Monzón, "An overview of material extrusion troubleshooting," Applied Sciences, vol. 10, no. 14, pp. 4776, 2020.
• [17] G.M. Gübitz, and A.C. Paulo, "New substrates for reliable enzymes: enzymatic modification of polymers," Current Opinion in Biotechnology, vol. 14, no. 6, pp. 577-582, 2003.
• [18] H. Ünal, S.H. Yetgin, and V.F. Ünal, "The Effect of glass beads content on the mechanical and microstructural behavior of glass beads filled polyamide-6.6 composites," Duzce University Journal of Science and Technology, vol. 11, no. 1, pp. 157-169. 2023
• [19] A. Oromiehie, and A. Mamizadeh, "Recycling PET beverage bottles and improving properties," Polymer International, vol. 53, no. 6, pp. 728-732, 2004.
• [20] S. Tall, A-C. Albertsson, and S. Karlsson, "Recycling of mixed plastic fractions: Mechanical properties of multicomponent extruded polyolefin blends using response surface methodology," Journal of Applied Polymer Science, vol. 70, no. 12, pp. 2381-2390, 1998.
• [21] J.M. Lagaron, and E. Núñez, "Nanocomposites of moisture-sensitive polymers and biopolymers with enhanced performance for flexible packaging applications," Journal of Plastic Film & Sheeting, vol. 28, no. 1, pp. 179-189, 2012.
• [22] S. Raha, H. Sharma, M. Senthilmurugan, S. Bandyopadhyay, and P. Mukhopadhyay, "Determination of the pressure dependence of polymer melt viscosity using a combination of oscillatory and capillary rheometer," Polymer Engineering & Science, vol. 60, no. 3, pp. 517-523, 2020.
• [23] I.L. Ali, N. Yunus, and M.I. Abu-Hassan, "Hardness flexural strength, and flexural modulus comparisons of three differently cured denture base systems," Journal of Prosthodontics, vol. 17, no. 7, pp. 545-549, 2008.
• [24] S-H. Chiu, and S-H. Pong, "In-line viscosity fuzzy control," Journal of Applied Polymer Science, vol. 79, no.7, pp. 1249-1255, 2001.
• [25] A. Marquez, J. Quijano, and M. Gaulin, "A calibration technique to evaluate the power-law parameters of polymer melts using a torque-rheometer," Polymer Engineering & Science, vol. 36, no. 20, pp. 2556-2563, 1996.
• [26] G. Janardhana Reddy, M. Kumar, and O. Anwar Beg, "Effect of temperature dependent viscosity on entropy generation in transient viscoelastic polymeric fluid flow from an isothermal vertical plate," Physica A: Statistical Mechanics and its Applications, vol. 510, pp. 426-445, 2018.
• [27] J-s. Wang, and R.S. Porter, "On the viscosity-temperature behavior of polymer melts," Rheologica Acta, vol. 34, no. 5, pp. 496-503, 1995.