The mechanics of the conform continuous extrusion process

The work describes the programme of activities relating to a mechanical study of the Conform extrusion process. The main objective was to provide a basic understanding of the mechanics of the Conform process with particular emphasis placed on modelling using experimental and theoretical considerations. The experimental equipment used includes a state of the art computer-aided data-logging system and high temperature loadcells (up to 260oC) manufactured from tungsten carbide. Full details of the experimental equipment is presented in sections 3 and 4. A theoretical model is given in Section 5. The model presented is based on the upper bound theorem using a variation of the existing extrusion theories combined with temperature changes in the feed metal across the deformation zone. In addition, constitutive equations used in the model have been generated from existing experimental data. Theoretical and experimental data are presented in tabular form in Section 6. The discussion of results includes a comprehensive graphical presentation of the experimental and theoretical data. The main findings are: (i) the establishment of stress/strain relationships and an energy balance in order to study the factors affecting redundant work, and hence a model suitable for design purposes; (ii) optimisation of the process, by determination of the extrusion pressure for the range of reduction and changes in the extrusion chamber geometry at lower wheel speeds; and (iii) an understanding of the control of the peak temperature reach during extrusion.

Assessment of Intramedullary Spinal Pressure in Small Breed Dogs With Thoracolumbar Disk Extrusion Undergoing Hemilaminectomy

OBJECTIVE To assess intramedullary spinal pressure (IMP) in small breed dogs with thoracolumbar disk extrusion. STUDY DESIGN Prospective cohort study. ANIMALS Small breed dogs (n = 14) with thoracolumbar disk extrusion undergoing hemilaminectomy and healthy chondrodystrophic laboratory dogs (control; n = 3) without spinal disease. METHODS Diagnosis was based on clinical and neurological examinations and magnetic resonance imaging (MRI) and was confirmed intraoperatively. A standardized anesthesia protocol and surgical procedure were used to minimize factors that could influence IMP. Intramedullary pressure was measured through a minidurotomy at the site of spinal cord compression using a fiber optic catheter inserted perpendicular to the longitudinal axis of the spinal cord. Measurements were taken after hemilaminectomy and again after removal of extruded disk material. RESULTS Affected dogs had significantly higher IMP compared to control dogs (P = .008) and IMP decreased significantly post-decompression compared with initial values (P < .001). No correlation was found between IMP and neurologic grade, degree of spinal cord compression on MRI, or signal intensity changes on MRI. CONCLUSION Acute thoracolumbar disk extrusion is associated with increased IMP in small breed dogs and surgical decompression results in an immediate decrease of IMP.

Low-temperature compaction of Ti-6Al-4V powder using equal channel angular extrusion with back pressure

Equal channel angular extrusion (ECAE), with simultaneous application of back pressure, has been applied to the consolidation of 10 mm diameter billets of pre-alloyed, hydride-dehydride Ti-6Al-4V powder at temperatures ≤400 °C. The upper limit to processing temperature was chosen to minimise the potential for contamination with gaseous constituents potentially harmful to properties of consolidated product. It has been demonstrated that the application of ECAE with imposed hydrostatic pressure permits consolidation to in excess of 96% relative density at temperatures in the range 100-400 °C, and in excess of 98% at 400 °C with applied back pressure ≥175 MPa. ECAE compaction at 20 °C (back pressure = 262 MPa) produced billet with 95.6% relative density, but minimal green strength. At an extrusion temperature of 400 °C, the relative density increased to 98.3%, for similar processing conditions, and the green strength increased to a maximum 750 MPa. The relative density of compacts produced at 400 °C increased from 96.8 to 98.6% with increase in applied back pressure from 20 to 480 MPa, while Vickers hardness increased from 360 to 412 HV. The key to the effective low-temperature compaction achieved is the severe shear deformation experienced during ECAE, combined with the superimposed hydrostatic pressure.

Deformation field variations in equal channel angular extrusion due to back pressure

Flow lines were analysed in aluminium alloy 6061 during equal channel angular extrusion (ECAE) in a 90° die with and without the application of back pressure during pressing. The lines appeared much more rounded when a back pressure was applied compared to the case of conventional ECAE testing. With the help of an analytic flow function, the deformation field was obtained. It is shown that back pressure slightly lowers the total strain, strongly increases the size of the plastic zone and significantly reduces the plastic strain rate.

A novel approach to dynamic modelling of polymer extrusion for improved process control

Polymer extrusion is a complex process and the availability of good dynamic models is key for improved system operation. Previous modelling attempts have failed adequately to capture the non-linearities of the process or prove too complex for control applications. This work presents a novel approach to the problem by the modelling of extrusion viscosity and pressure, adopting a grey box modelling technique that combines mechanistic knowledge with empirical data using a genetic algorithm approach. The models are shown to outperform those of a much higher order generated by a conventional black box technique while providing insight into the underlying processes at work within the extruder.

The inferential monitoring of the screw disturbance torque to predict process fluctuations in polymer extrusion

Polymer extrusion is one of the major methods of processing polymer materials and advanced process monitoring is important to ensure good product quality. However, commonly used process monitoring devices, e.g. temperature and pressure sensors, are limited in providing information on process dynamics inside an extruder barrel. Screw load torque dynamics, which may occur due to changes in solids conveying, melting, mixing, melt conveying, etc., are believed to be a useful indicator of process fluctuations inside the extruder barrel. However, practical measurement of the screw load torque is difficult to achieve. In this work, inferential monitoring of the screw load torque signal in an extruder was shown to be possible by monitoring the motor current (armature and/or field) and simulation studies were used to check the accuracy of the proposed method. The ability of this signal to aid identification and diagnosis of process issues was explored through an experimental investigation. Power spectral density and wavelet frequency analysis were implemented together with a covariance analysis. It was shown that the torque signal is dominated by the solid friction in the extruder and hence it did not correlate well with melting fluctuations. However, it is useful for online identification of solids conveying issues.