Warning: Trying to access array offset on value of type bool in /www/doc/www.compuplast.tech/www/wp-content/plugins/edge-cpt/shortcodes/imagegallery/image-gallery.php on line 239

Warning: Trying to access array offset on value of type bool in /www/doc/www.compuplast.tech/www/wp-content/plugins/edge-cpt/shortcodes/imagegallery/image-gallery.php on line 239

Warning: Trying to access array offset on value of type bool in /www/doc/www.compuplast.tech/www/wp-content/plugins/edge-cpt/shortcodes/imagegallery/image-gallery.php on line 239
logo
A powerful architecture & Construction theme. Construct your website in the perfect Ratio.
Alienum phaedrum torquatos nec eu, vis detraxit periculis ex, nihil expetendis in mei. Mei an pericula
office@compuplast.tech
+420 577 220 451
Svat. Čecha 293, 760 01 Zlín
mobile logo

Problems with final product quality

COMPUPLAST® SOFTWARE / Problems with final product quality

Consistent product quality is essential in extrusion processes, yet even minor imbalances in flow can lead to costly defects. In this case, a customer faced irregularities in the final profile geometry. Using 2D FEM simulation, our team revealed an uneven pressure distribution inside the extrusion die. With a new die design, the issue was resolved, resulting in stable, high-quality output.

What was the problem? Defects in a film product!

Defects were appearing in a 5-layer, coextruded, film product. Using microscopic analysis it was determined that the defects were occurring in one particular layer and upon further analysis, the defects were determined to be “gels” formed by degraded polymer. Based on the orientation and appearance of the defects, we advised the customer to examine the extruder screw for that layer. The following image shows the fluted mixing section of the screw.

The above image clearly shows the discoloration in the channels that typical results from polymer degradation (burning).

What was the root cause? Poorly designed mixing element!

The following image shows the shear stress in the mixing section of the screw, as predicted by the VEL™ Extruder module simulation.

The analysis of the simulation results indicated that the fluted mixer was not designed correctly (for the particular polymer and process conditions) and thus, the mixer did not have adequate “self-cleaning” ability. Consequently, the polymer experienced a very long residence time in the mixer which led to the degradation(burning) and, ultimately, the defect that appeared on the final product.

How it was solved? Improve the design of the fluted mixer!

Using the VEL™ Extruder module, the mixer design was improved/optimized, for the particular polymer and processing conditions, so that it had sufficient “self-cleaning” ability. Thus, the residence time on the surface was reduced and the degradation(burning) was eliminated which eliminated the defects in the film.

Bottom Line

Normally, it would have taken a long time to simply figure out where the problem was coming from. Using our experience, and simulation capabilities, we were quickly able to find the root cause of the problem. Once the source of the problem was understood, we were able to use the VEL™ Extruder module to, quickly and efficiently, find an optimized solution. Of course, optimizing the mixer (and screw) design, prior to manufacturing, could have avoided the problem (and the customer’s frustration) all together.