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Rubber Extrusion Technology
Course Number: AP4206
Date: 07/24/2013 - 07/26/2013
Time: 8:00 AM - 4:00 PM
Location: Akron Polymer Training Center, Akron, OH 44325-5404
Cost:
$1800 USD
CEU's: 2.25
Instructor: Jim Stevenson and John Dick
Course Overview
This 3-day course provides useful basic information on all aspects of rubber extrusion technology. Extrusion fundamentals are presented and then clearly demonstrated by examples. This course makes use of the most comprehensive set of public data, mostly in graphical form, within the rubber extrusion industry.
The immense variety of materials, equipment and operations within the rubber extrusion industry are given a common basis by grouping topics into the following categories:
Compound ingredients, characterization, and processing
Equipment for pumping, shaping (including die design), curing and hose manufacture
Instruments for characterizing extrusions on and offline
Operating characteristics of extruders, curing ovens, conveyors
Procedures to insure high production rates and quality
Process variation and control of product size and shape (multiple dimensions)
The Rubber Extrusion Technology (RET) course notes conclude with a troubleshooting guide systematically covering problems, causes and corrective actions as presented in the course. RET benefits teams involved in Six Sigma programs by providing cause and effects relations essential for DOEs, FMEAs, QFDs and other quality procedures. Past participants have praised the number of useful approaches to solving current problems that are presented in RET.
RET is targeted to benefit materials and process engineers, die designers, quality control personnel, and supervisors and managers responsible for these functions. The course is valuable to those responsible for specifying equipment and particularly individuals new to the rubber extrusion industry or who have recently been promoted.
Companies receive an added advantage by sending personnel in groups or over an extended period of time. Course attendees working together with the same knowledge base will be more in tune with each other and more productive.
Course Outline
(Not all topics are covered because of participant preferences and time constraints.)
I. MATERIALS
A. Elastomer Properties
1. Chemical Structure
2. Molecular Weight/Distribution
3. Morphology and Crystallinity
4. Viscosity (Flow)
a. Shear Rate
b. Temperature
c. Slip
5. Elasticity (Swell)
a. Shear Stress
b. Die L/D
6. Scorch
B. Laboratory Tests for Extrudability
1. Mooney Viscometer
2. Processability Testers
3. Standard Dies (Garvey)
4. State of
C. Compound Ingredients
1. Elastomers
2. Fillers
3. Plasticizers and Process Aids
4. Cure Systems/Nitrosamines
D. Processing and Compounding
1. EPDM
2. Polychloroprene (Neoprene)
3. SBR/BR
4. Nitrile Rubber
5. Chlorosulfonated Polyethylene
6. Silicone Rubber
7. Fluoroelastomers
II. PUMPING EQUIPMENT
A. Rotating Pumps
1. Rubber Processes
a. Unit Operations
b. Hot &
2. Barrels
a. Construction
b. Materials
c. Heat Transfer
3. Screws
a. Construction
b. Materials
4. Process Machine Design
5. Single-Stage Extruders
a. Hot Feed
b. Barrier Screws
c. Superposed Flights
d. Multicut Transfermix
e. Pin Barrel
f. Pin Transfermix
g. Thermoplastic Elastomer
h. Gear Extruder
6. Two-Stage Extruders
7. Mixing Pumps
8. Continuous Mixers
9. Twin Screw Extruders
10. Feed Devices
B. Ram (Preform) Extruder
C. Auxiliary Devices
1. Shear Heads
2. Gear Pumpus
D. Temperature Control
III. SHAPING EQUIPMENT
A. Heads
1. Inline Heads
2. Crossheads
3. Tire Heads
4. Breaker Plates & Screen Changers
5. Directed Flow Head
a. Curved Extrusion
b. Takeaways
c. Rapid Die Change
d. Dimensional Control
B. Dies
1. Types and Design Criteria
2. Flow Dynamics
a. Viscosity
b. Pressure-Flow Relations
c. Swell
3. Drawdown
4. Sheet Dies
a. Single Roller Die
b. Double Roller Die
5. Profile Dies
a. Product Design
b. Die Design
c. Die Operation
d. Coextrusion Dies
e. Coating Dies
f. Orientation Control
6. Design Computations
a. Annulus & Flange
b. Keyhole Die Internals (Flow)
c. Tube with Side Feed
d. Die with Carrier
e. Coextrusion Dies with Swell
7. Die Relief Strategies
a. Straight Cut
b. Back Relief
c. Face Relief
8. Finite Element Simulations
IV. DOWNSTREAM EQUIPMENT
A. Continuous Cure (Low Pressure)
1. Compounding
2. Salt
3. Hot Air
4. Microwave
B. Batch Cure
1. Autoclave
2. Hose Vulcanization
C. Hose Manufacture
1. Construction
2. Materials
3. Reinforcement
4. Curved Hose
V. INSTRUMENTATION
A. Instrumented Extrusion Line
B. Temperature Sensors
1. Thermocouples
a. Fixed
b.
2. Resistance Devices (RTDs)
3. Thermistors
4. Infrared Probes
C. Pressure Sensors
1. Strain Gauge
2. Piezoelectric
D. Dimension Sensors
1. Lasers
a. Blocked Beam
b. Linear Profile
c. 360° Profile
2. Ultrasonic Devices
3. Electromechanical Devices
4. Diode Array
5. Length
6. Coating Thickness
7. X-ray
E. Weight and Area Sensors
1. Scales
2. Radiation
VI. OPERATIONS
A. Extruder Dynamics
1. Flow in Screw Pumps
2. Output Rate Dependence
a. Screw Speed
b. Temperature Set Points
c. Die Resistance
3. Operating Curves
4. Heat Transfer
5. Output
a. Screw Speed
b. Temperature Set Points
c. Die Resistance
6. Conveyor Operation
a. Variability
b. Contraction
7. Extrudate Curvature
a. Flow
b. Swell
c. Relaxation
d. WindUp
B. Productivity and Quality
1. Optimum Conditions
a. Quality Measurement
b. Screw Type/Speed
c. Barrel/ScrewTemperature
d. Feed Conditioning
2. Feed Strip Geometry
3. Feed Mill Operation
4. Adjustments on Pin Barrels
a. Pin Removal
b. Mixing Capability Test
5. Screw and Barrel Wear
a. Causes of Wear
b. Characteristics of Wear
c. When to Change
d. Measurement
e. Maintenance
6. Starved Operation
a. Mechanisms
b. Evidence
c. Remedies
7. Die Drool
VII. Process Variation & Control
A. Variation
1. Sources of Variation
2. Root Cause by Crosscorrelation
B. Control
1. Feedback Control
2. Size Control
a. Line Speed
b. Screw Speed
3. Shape Control (One Component)
a. Die Temperature
b. Stock Temperature
c. Adjustable Dies
4. Shape Control (Multicomponent)
5. Commercial Controls
a. Systems
b. Wireless
VIII. TROUBLESHOOTING
A. Introduction
B. Product Geometry
1. Surface Defects
2. Lumps
3. Porosity
4. Dimensional Variability
C. Extruder Operation
1. Safety
2. Output Rate
3. Temperature
4. Vent Plugging
5. Wear
6. Die Drool
D. Compound
IX. REFERENCES
A. Books
B. Paper
Course Registration
General Course Registration:
Download a Printable Registration Form [PDF].
Registration Information:
Registration for a class is due three weeks prior to the scheduled class date.
All registrations must be guaranteed by check, a purchase order number or a credit card, otherwise the registration will not be processed. Checks should be made payable to: The Akron Polymer Training Center and must include a copy of your completed registration form. COURSE FEES ARE DUE PRIOR TO ATTENDING.
All registrations whether by phone, fax or mail will be confirmed and considered binding and subject to all cancellation policies. If you do not receive a confirmation prior to the class, please call The Akron Polymer Training Center to verify your registration.
Course fee includes classroom instruction, instructional materials, parking permits and refreshment breaks. Travel and hotel accommodations are not included.
ENROLLMENT IS LIMITED AND ON A FIRST-COME, FIRST-SERVE BASIS. EARLY REGISTRATION IS STRONGLY RECOMMENDED!
Visit our registration webpage to view our cancellation/withdrawal policies.
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Akron, OH 44325
Phone: 330-972-7111
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