Various references have hitherto been made on screw characteristics of an extruder for molding Newtonian viscous materials. Recently the Bingham plastic matcrial was made an object of an advanced research. In some cases the extruding process was investigated in these references as an isothermal one, while in others, as an adiabaticone. In practising extrusion of molten plastics, however, it was assumed that an ideal temperature distribution was obtained along the screw axis mostly by heating the location, paying due regards to the properties of the material to be molded.
In this research of ours was attempted “a graphical representation of screw characteristics of an extruder for molding pseudoplastic materials” based on the data on flow characteristics of the materials, dimensions of the screw and temperature distribution thereof.
Analysis was made on the assumption that the materials did not slip on the surface of the screw and barrel, but flowed in accordance with the Rabinowitsch rheological equation (Eq. 1). With the aid of the following non-dimensional terms,
(6)
a non-dimensional diagram (Fig.3) was drawn up. For any cross section of screw channel, the values of S, h, m and η were found to remain constant. Hence, the values of σ and w were calculated for constant Q
m=60
ρQ and V (or N) and the values of z obtained by consulting Fig.3. In the like manner, the value of ξ in that section of screw channel was obtained. Thus, for any constant N, each ξ-distribution curve along the screw channel would be drawn in reference to respective Q
M as shown in Figs.8-12.
It may be assumed that the pressure rise begins at that section of screw channel that fills first of all with the perfectly molten materials. We call the distance from this section to the screw front along the middle of screw channel “Melt Length”. The area enclogd by the ξ-distribution curve and the “Melt Length” gives the pressure rise P for N and Q
M. Plotting the points (P, Q
M) for constant N, the screw characteris tics were represented in lines as shown in Fig.13. Fig.8-12 are made for polyethylene whose flow charxteristics are shown in Fig.5, and for an experimental extruder of compression type as shown in Fig.1. Temperature distribution is assumed as shown in Figs.8-12.
For polyethylene the melting point is 110-115°C, and assuming that the distance from the section in which the temperature is 130°C, as judged from the motion of the materials and from the existence of the short transient region in a state bitween pellet and fluid, to the screw front to be the “Melt Length, ” we obtained the screw characteristics (dotted lines in Fig.13) which lie in the neighbourhood of experimental data. Furthermore, by amending the “Melt Length” by the experimental data (Fig.6), we obtained the amended screw characteristics (chain lines in Fig.13) which show good approximation to the experimental data.
Change of screw characteristics, by the way, due to a slight difference in the “MeltLength” is small. Consequently this graphical representation of screw characteristics may be available for design of a screw extruder and selection of operating conditions thereof when molding pseudoplastic materials like polyethylene which flow according to the Rabinowitsch rheological equation and do not slip on the surface of the screw and barrel.
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