How To Maximize Your Screw and barrel life?
Date:2022-6-09 Author:hcscrew
Maximising the effective lifetime of the extruder screw and barrel has long been of interest.
Reduced residence time of the material in the screw can result in uneven mixing and plasticization. The material may be heated rapidly and decomposed thermally if it is excessively sheared. If the stability of the extrusion cannot be controlled, the size of the extrudate will vary. To improve accuracy, control devices and associated auxiliary devices must be updated. Screws and barrels are subject to increased wear, so high and ultra-high wear-resistant materials are needed. A solution to increasing the life of bearings and reducers at high speeds must be found.
Plastics processors can gain an advantage by incorporating some relatively simple practises into their operations. In the extrusion process, the screw and barrel need to be designed to maximise melt efficiency. The important point is the gap between the barrel wall’s inner diameter and the screw prongs’ outer diameter. These gaps are usually extremely small, which allows the screw to achieve good heat transfer and shear rates.
Once the screw starts to rotate in the barrel, wear occurs. This wear can occur on either the screw prongs or the barrel surface, or both. In either case, whether it is abrasive filler in the polymer or stray metal particles not in the melt stream. Harder the material, the faster it will wear, and the wider the original gap will be. As the gap increases, the melting efficiency decreases. In cases where melt efficiency begins to decrease below the original setting, many operators increase screw speed, barrel temperature, back pressure, or a combination of these adjustments.
Making these adjustments can help operators trying to avoid longer cycles, unmelted material, higher melt temperatures or higher scrap rates. Unless they significantly affect products or production efficiency, these changes are usually gradual and hard to notice.
When plasticisation rates, productivity or scrap rates reach unacceptable levels, the process engineer will begin to look for the cause. At this point, it may not be possible to do a quick overhaul unless there is a spare screw or barrel nearby. Spare parts are usually available within a day or two. If not, the machine must be shut down or run at reduced efficiency until a spare part can be found and installed.
Here are some ways to maximize the effective life of the screw and barrel. For further engineering support regarding extruder screw and barrel, please feel free to contact us at HUACHEN Screw Barrel.
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