Defects
Die swell
𝐷2 −𝐷1
Die swell = , where 𝐷1 is the inner diameter of the die and 𝐷2 is the
𝐷1
average outer diameter of the extruded part.
Die swell can vary from 10% to over 100% increase in dimensions depending on:
1. Material
2. Melt temperature
3. Extrusion speed
4. Die geometry
Die swell
Notes:
How to avoid ?
Drawdown: The size of the designed die dimensions relative to the final part
dimensions. The dimensional ratio of the die to final part is used to offset the
“swell” of the thermoplastic as it exits the die.
Land length: The length of the steel (of die) that runs parallel to the polymer
flow. The land-length ratio is the ratio of the land length to the die gap (wall
thickness).
Die swell
Differences between the shape of the die and the extruded section:
Die swell
Remedies:
Such a surface will improve if run more slowly if moisture is not
the problem, so we need to avoid the over-speed of extrusion.
Vents and vacuum hoppers will eliminate trapped air and are
essential for powders, where passages between the particles are
much smaller; the air cannot escape back through these passages
and is carried forward instead.
Causes: Degradation of Polymer
Overheating may produce degradation of the polymer material that is used.
The degradation varies from one polymer to the other.
For example, PVC is the most susceptible to degradation as its processing
temperature is always close to its decomposition temperature.
This degradation might cause the polymer to produce gases that might
become trapped inside the material.
Causes: Degradation of Polymer
Remedies:
Avoid overheating and make sure that the temperature we heat the polymer is safe
and causes no degradation.
Very accurate temperature control is needed for materials susceptible to
degradation.
Causes: Depolymerization of Polymer
“When there are problem handling fluid polymers it is often advisable to change
to a higher molecular weight grade of polymer”
PVC :
Flow Direction
Shark skin tends to be reduced with
increase in temperature
Shark-Skin : Pressure Plateau
Through the lower region of the curve, melt flow is steady and bottle surfaces are
smooth
As melt pressure continues to increase, suddenly sharkskin occurs.
if extrusion pressure is raised still further, the sharkskin disappears. Actually, neither
the parison nor the bottle is quite as smooth as one produced in the steady-flow
region.
Melt Fracture:
When polymer melts pass round a spider leg and or through a breaker plate
the molten material is separated. unless there is a high pressure on the side
of the spider and /or breaker plate the separated melt will not fully knit
together and lines or planes of weakness willoccur.
The head pressure may be increased by:
Increased the die land reducing the cross sectional area at the die
lowering the die temperatur
Plate-Out :
When extruding polymers, additives are sometimes deposited from the melt
onto the forward part of the screw and onto the extruder head and die. This
effect is know as plate- out and is most frequently met within PVC. Deposition
occur s most frequently in regions of high temperature and high shear.
Formulation also has an important influence.
This can be reduced by:
lowering the die head temperature
reducing extrusion speed
change the formulation
Reference:
https://www.lyondellbasell.com/globalassets/documents/polymers-
technical-literature/tech-topic-sharkskin.pdf?id=13883