Extrusion Project Proposal Final
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DESIGN, FABRICATION AND TESTING OF PLASTIC EXTRUSION MACHINE
Team Members: BISHWAJEET SHRESTHA
(071/BME/411)
MANOJ BHUSAL
(071/BME/420)
SHASHI SHAH
(071/BME/438)
YUVRAJ SHRESTHA
(071/BME/446)
12/25/2017
1
1. INTRODUCTION 1.1 Objectives: Main Objective: • To design, fabricate & test the Plastic Extruder Machine. Special Objectives: • To research and test different types of waste plastic’s pallets on extruder machine. • To produce plastic filaments from our surrounding plastic waste. • To test the produced plastic filaments on 3D printer. 12/25/2017
2
1.2 Background: • Plastic extrusion machine is a machine which melts plastic flakes inserted into the hopper and extrudes it into a line of plastic. • Extrusion machine can create filament, granulate or creative art working with moulds. • Blends differently colored plastics together and outputs a homogeneous and smooth color. • Increases recyclability of plastics.
12/25/2017
3
1.3 Problem Statement: • Daily use of plastics are increasing day to day. • The plastics industry releases 14% of the total toxic gas that went into the air. • The filaments we use for 3D printer is manufactured from synthesis of raw materials on industry and are costly. • Waste plastics causes environment pollution due to its stability.
12/25/2017
4
1.4 Justification: • All plastic laying around is a resource with great potentials and opportunities waiting to be discovered. • Opportunity to eliminate plastic pollution by creating something new. • Fabrication of plastic extrusion machine is a small step towards the plastic waste management. • Our project aim is to make optimum use of local waste plastic resource into something usable, acceptable and affordable.
12/25/2017
1.5 Expected Outcomes: • Development of an affordable plastic extrusion machine. • Extrusion of plastic will be easier and economical as compared to the industrial method of extrusion. • Encouragement towards locally manufactured products from available plastic resources. • Import from other countries will decrease.
12/25/2017
6
2. METHODOLOGY
12/25/2017
7
3. LITERATURE REVIEW This section lists different modes of extrusion and general products of an extrusion process.
12/25/2017
8
EXTRUSION THEORY: The extruder can be considered as one of the core piece of machinery in the plastic processing industry. To extrude means to thrust out a plastic material in any kind of form with the desired cross-section through a die. The shape of material will depend on the die opening, and it will change to some extent as it exits from the die. The extruder output is commonly referred to as the extrudate.
PLASTIC TYPES: 1. Polyethylene Terephthalate (PET or PETE): Properties: Clarity, lightness, strength, toughness, a barrier to liquid and gas.
12/25/2017
9
2. High-density polyethylene (HDPE): Properties: Stiffness, strength, toughness, resistance to moisture, permeability to gas, ease of processing.
3. Polyvinyl chloride (PVC): Properties: Versatility, ease of blending, strength, toughness, clarity, transparency.
12/25/2017
10
4. Low-Density Polyethylene (LDPE): Properties: Strength, toughness, flexibility, resistance to moisture, ease of sealing, ease of processing.
5. Polypropylene (PP): Properties: Strength, toughness, resistance to heat, chemicals, grease & oil, barrier to moisture.
12/25/2017
11
6. Polystyrene (PS): Properties: Versatility, clarity, easily formed.
FLOATING PROPERTIES OF PLASTIC:
12/25/2017
12
COMMON PROPERTIES OF PLASTICS:
12/25/2017
13
PHYSICAL PROPERTIES:
12/25/2017
14
PRODUCTION LINE: A general production extrusion line consists of: 1. Hopper 2. Barrel 3. Nozzle 4. Nozzle screw 5. Nozzle filter 6. Nozzle flow adjuster 7. Barrel holder 7. Barrel shaft 8. Extrusion framework 9. Extrusion electronic 12/25/2017
15
Different Types of Extruders: There are mainly 4 types of filament extruders: a. Single screw extruders
Screw Extruders (continuous) b. Multi screw extruder
Spiral disk extruder, Disk pack extruder Drum extruder Stepped disk extrude
b. Elastic melt extruders
Screw less extruder Screw or disk type melt extruder
Ram extruders
Reciprocating single screw extruders 12/25/2017
Twin screw extruders Gear pumps Planetary gear extruders multi(>2) screw extruders
a. Viscous drag extruders
Disc or Drum Extruders (continuous)
Reciprocating Extruders (Discontinuous)
Melt fed , Plasticating Single stage Multi stage Compounding
Melt fed extruder Plasticating extruder Capillary rheometer Plasticating unit in injection molding machines Compounding extruders (The Kneader) 16
1. Single Screw Extruders: • These contains single screw to compress and extrude the materials.
2. Multi-screw Extruders: In a general description, a multi-screw extruder is an extruder consisting of more than one Archimedean screws. The early twin screw extruders, developed by Roberto Colombo and Carlo Pasquetti in the late 1930s.
12/25/2017
17
3. Disc Extruder:
• Disk extruders are among the types of extruders that do not utilize an Archimedean screw for the transport of the material. • Disk extruder was invented in 1950.
4. Ram Extruders:
• Ram extruders are normally simple extruders • These contain ram to press the material.
12/25/2017
18
GENERAL PRODUCTS OF EXTRUSION: 1. Pipes Extrusion: Generally PVC pipes, electricity pipes, water pipes etc. 2. Plastic Films: Food packaging plastics, wrapping plastics 3. Extrusion Coating and Laminating: In this method,secondary objects are coated and laminated by plastic. 4. Cable Coating: Cable insulation and the coating is also done by an extruder. 5. Extrusion Blow Molding:
12/25/2017
19
DIFFERENT SIZES OF EXTRUDERS: 1. Laboratory Extruder: Laboratory extruders are suitable for Laboratory Testing, Research. 2. Pilot Extruder: The pilot screw extruders have been able to produce thinner profiles but the machine’s heating power is not enough to melt large amounts of material quickly. 3. Production Extruder: Production extruders are of large scale which are used in mainly mass product extrusion.
12/25/2017
20
4. DESIGN CONCEPT Technical Drawing:
Fig: Drawing of Plastic Extruder.
Figure: Model of Plastic Extruder.
12/25/2017
21
5.BUDGET PLANNING S.N.
Description
Details
Quantity
Price(Rs.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Mechanical parts Strip Round bar Round bar Square tube Tube Angle profile Sheet metal Motor Bearings Drill
30x3 mm 30 mm 25 mm 30x30x3 mm 34x26x4 mm 30x30x3 mm 1 mm 70 rpm UCFL 204 26 x 600 mm
10 cm 5.5 cm 22 cm 800 cm 53 cm 32 1 1 1
120 250 365 4250 120 250 1850 3650 600 3500
11. 12. 13. 14. 15. 16. 17. 18.
Electronics parts PID controllers SSR Thermocouple Band heater Band heater Power switch Led indicator Electrical wire
0-400 Degree 2-24 V Type K 35x45 mm 40x45 mm 220 V 220 V
2x 2x 2x 3x 1x 1x 1x 5m
2400 1000 1800 2200 1000 350 350 250
19. 20. 20.
Others Labor cost Field visit and snacks 12/25/2017 Miscellaneous
22
5000 2000 695
6. TIME SCHEDULING: 6.1. Tabulated Time Schedule:
12/25/2017
23
6.2 Gantt Chart:
12/25/2017
24
7. REFERENCES: 1. Chapters. (n.d.). Retrieved December 12, 2017, from https://preciousplastic.com/en/videos/build/extrusion.html 2. Materials. (n.d.). Retrieved December 12, 2017, from https://www.spiratex.com/products_category/materials/ 3. (2014, August 21). Starting up plastic extrusion buss Kanya auvinen degree thesis. Retrieved December 12, 2017, from https://www.slideshare.net/ahmad25may1/kanya-auvinen-degreethesis
12/25/2017
25
Team Members: BISHWAJEET SHRESTHA
(071/BME/411)
MANOJ BHUSAL
(071/BME/420)
SHASHI SHAH
(071/BME/438)
YUVRAJ SHRESTHA
(071/BME/446)
12/25/2017
1
1. INTRODUCTION 1.1 Objectives: Main Objective: • To design, fabricate & test the Plastic Extruder Machine. Special Objectives: • To research and test different types of waste plastic’s pallets on extruder machine. • To produce plastic filaments from our surrounding plastic waste. • To test the produced plastic filaments on 3D printer. 12/25/2017
2
1.2 Background: • Plastic extrusion machine is a machine which melts plastic flakes inserted into the hopper and extrudes it into a line of plastic. • Extrusion machine can create filament, granulate or creative art working with moulds. • Blends differently colored plastics together and outputs a homogeneous and smooth color. • Increases recyclability of plastics.
12/25/2017
3
1.3 Problem Statement: • Daily use of plastics are increasing day to day. • The plastics industry releases 14% of the total toxic gas that went into the air. • The filaments we use for 3D printer is manufactured from synthesis of raw materials on industry and are costly. • Waste plastics causes environment pollution due to its stability.
12/25/2017
4
1.4 Justification: • All plastic laying around is a resource with great potentials and opportunities waiting to be discovered. • Opportunity to eliminate plastic pollution by creating something new. • Fabrication of plastic extrusion machine is a small step towards the plastic waste management. • Our project aim is to make optimum use of local waste plastic resource into something usable, acceptable and affordable.
12/25/2017
1.5 Expected Outcomes: • Development of an affordable plastic extrusion machine. • Extrusion of plastic will be easier and economical as compared to the industrial method of extrusion. • Encouragement towards locally manufactured products from available plastic resources. • Import from other countries will decrease.
12/25/2017
6
2. METHODOLOGY
12/25/2017
7
3. LITERATURE REVIEW This section lists different modes of extrusion and general products of an extrusion process.
12/25/2017
8
EXTRUSION THEORY: The extruder can be considered as one of the core piece of machinery in the plastic processing industry. To extrude means to thrust out a plastic material in any kind of form with the desired cross-section through a die. The shape of material will depend on the die opening, and it will change to some extent as it exits from the die. The extruder output is commonly referred to as the extrudate.
PLASTIC TYPES: 1. Polyethylene Terephthalate (PET or PETE): Properties: Clarity, lightness, strength, toughness, a barrier to liquid and gas.
12/25/2017
9
2. High-density polyethylene (HDPE): Properties: Stiffness, strength, toughness, resistance to moisture, permeability to gas, ease of processing.
3. Polyvinyl chloride (PVC): Properties: Versatility, ease of blending, strength, toughness, clarity, transparency.
12/25/2017
10
4. Low-Density Polyethylene (LDPE): Properties: Strength, toughness, flexibility, resistance to moisture, ease of sealing, ease of processing.
5. Polypropylene (PP): Properties: Strength, toughness, resistance to heat, chemicals, grease & oil, barrier to moisture.
12/25/2017
11
6. Polystyrene (PS): Properties: Versatility, clarity, easily formed.
FLOATING PROPERTIES OF PLASTIC:
12/25/2017
12
COMMON PROPERTIES OF PLASTICS:
12/25/2017
13
PHYSICAL PROPERTIES:
12/25/2017
14
PRODUCTION LINE: A general production extrusion line consists of: 1. Hopper 2. Barrel 3. Nozzle 4. Nozzle screw 5. Nozzle filter 6. Nozzle flow adjuster 7. Barrel holder 7. Barrel shaft 8. Extrusion framework 9. Extrusion electronic 12/25/2017
15
Different Types of Extruders: There are mainly 4 types of filament extruders: a. Single screw extruders
Screw Extruders (continuous) b. Multi screw extruder
Spiral disk extruder, Disk pack extruder Drum extruder Stepped disk extrude
b. Elastic melt extruders
Screw less extruder Screw or disk type melt extruder
Ram extruders
Reciprocating single screw extruders 12/25/2017
Twin screw extruders Gear pumps Planetary gear extruders multi(>2) screw extruders
a. Viscous drag extruders
Disc or Drum Extruders (continuous)
Reciprocating Extruders (Discontinuous)
Melt fed , Plasticating Single stage Multi stage Compounding
Melt fed extruder Plasticating extruder Capillary rheometer Plasticating unit in injection molding machines Compounding extruders (The Kneader) 16
1. Single Screw Extruders: • These contains single screw to compress and extrude the materials.
2. Multi-screw Extruders: In a general description, a multi-screw extruder is an extruder consisting of more than one Archimedean screws. The early twin screw extruders, developed by Roberto Colombo and Carlo Pasquetti in the late 1930s.
12/25/2017
17
3. Disc Extruder:
• Disk extruders are among the types of extruders that do not utilize an Archimedean screw for the transport of the material. • Disk extruder was invented in 1950.
4. Ram Extruders:
• Ram extruders are normally simple extruders • These contain ram to press the material.
12/25/2017
18
GENERAL PRODUCTS OF EXTRUSION: 1. Pipes Extrusion: Generally PVC pipes, electricity pipes, water pipes etc. 2. Plastic Films: Food packaging plastics, wrapping plastics 3. Extrusion Coating and Laminating: In this method,secondary objects are coated and laminated by plastic. 4. Cable Coating: Cable insulation and the coating is also done by an extruder. 5. Extrusion Blow Molding:
12/25/2017
19
DIFFERENT SIZES OF EXTRUDERS: 1. Laboratory Extruder: Laboratory extruders are suitable for Laboratory Testing, Research. 2. Pilot Extruder: The pilot screw extruders have been able to produce thinner profiles but the machine’s heating power is not enough to melt large amounts of material quickly. 3. Production Extruder: Production extruders are of large scale which are used in mainly mass product extrusion.
12/25/2017
20
4. DESIGN CONCEPT Technical Drawing:
Fig: Drawing of Plastic Extruder.
Figure: Model of Plastic Extruder.
12/25/2017
21
5.BUDGET PLANNING S.N.
Description
Details
Quantity
Price(Rs.)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Mechanical parts Strip Round bar Round bar Square tube Tube Angle profile Sheet metal Motor Bearings Drill
30x3 mm 30 mm 25 mm 30x30x3 mm 34x26x4 mm 30x30x3 mm 1 mm 70 rpm UCFL 204 26 x 600 mm
10 cm 5.5 cm 22 cm 800 cm 53 cm 32 1 1 1
120 250 365 4250 120 250 1850 3650 600 3500
11. 12. 13. 14. 15. 16. 17. 18.
Electronics parts PID controllers SSR Thermocouple Band heater Band heater Power switch Led indicator Electrical wire
0-400 Degree 2-24 V Type K 35x45 mm 40x45 mm 220 V 220 V
2x 2x 2x 3x 1x 1x 1x 5m
2400 1000 1800 2200 1000 350 350 250
19. 20. 20.
Others Labor cost Field visit and snacks 12/25/2017 Miscellaneous
22
5000 2000 695
6. TIME SCHEDULING: 6.1. Tabulated Time Schedule:
12/25/2017
23
6.2 Gantt Chart:
12/25/2017
24
7. REFERENCES: 1. Chapters. (n.d.). Retrieved December 12, 2017, from https://preciousplastic.com/en/videos/build/extrusion.html 2. Materials. (n.d.). Retrieved December 12, 2017, from https://www.spiratex.com/products_category/materials/ 3. (2014, August 21). Starting up plastic extrusion buss Kanya auvinen degree thesis. Retrieved December 12, 2017, from https://www.slideshare.net/ahmad25may1/kanya-auvinen-degreethesis
12/25/2017
25
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