Extrusion Observations on 11/06/2003
M. Kostic
www.kostic.niu.edu/extrusion email: kostic@niu.edu
Photo record of 11/06/2003 extrusion parameters (*for SET Value, click on Photo # to see photo):
Photo | Time A/PM | P1 | P2 | P3 | Motor %load | KTRON1 kg/hr | KTRON2 kg/hr | Pull cm/sec | Tmelt C | Tvac C | Tspray C | NOTE |
09:36 | 0 | 1 | 0 | 0 | *50.0 | *0.50 | 7.452 | 192 | 18 | 16 | Heating No run | |
10:21 | 818 | 513 | 362 | 53.0 | 6.98 | |||||||
10:24 | 1399 | 1091 | 347 | 61.8 | ||||||||
11:26 | 457 | 156 | 375 | 50.0 | 6.01 | |||||||
11:26 | 52.26 *52.049 | |||||||||||
11:26 | 0.565 *0.516 | |||||||||||
11:27 | 301 *300 | (0.21R) | ||||||||||
11:27 | 608 | 299 | 381 | 54.9 | ||||||||
11:27 | 274 *300 | (0.21R) | ||||||||||
11:28 | 644 | 334 | 382 | 54 | 6.012 | 213 | 15 | 16 | 103rpm | |||
11:29 | 529 (532) | 224 (226) | 379 (381) | 53.8 (55) | 6.012 | 213 | 15 | 16 | 103rpm (layout) | |||
11:31 | Melt photo | |||||||||||
11:32 | -||- | |||||||||||
11:49 | 580 | 273 | 381 | 50.5 | 5.80 | |||||||
12:01 | 533 | 229 | 384 | 50.8 | 5.90 |
The following samples are taken for dimensional inspection (times were not recorded) by Dan Wu:
Sample Serial No. | Puller Speed (cm/sec) | Vacuum | Air (but N2) |
1S | 6 | 1.8 | 2.8 |
2S | 5.9 | 1.8 | 2.8 |
3S | 5.9 | 1.8 | 4 |
4S | 5.9 | 1.8 | 3 |
5S | 5.9 | 1.8 | 7 |
6S | 5.9 | 1.8 | 6 |
7S | 5.9 | 1.8 | 5 |
8S | 5.8 | 1.8 | 5 |
M. Kostic’s comments: I believe that vacuum was changed later up to 2.5 in H2O. The hole was pressurized with Nitrogen (referred as air by mistake). The serial numbers (1S to 8S) are probably not sequential since the puller speed was not the smallest at the end, and I am not sure in what order the Nitrogen pressure was changed. Could you comment whether all labeling was accurate or some might be uncertain. Next time we should be prepared for labeling, may be with a “logical form” to be field-in during the extrusion runs. Dan should sketch (or scan, photograph) and measure the samples, and give some verbal description, what changed on the samples due to process-parameter change, and preliminary reasoning (why!). We should also summarize the extrudate temperature measurements taken by Dan and Prasad.
The other process parameters (to be confirmed by Fermilab):
KTRON loop mass flow rate: 50 kg/hr (KTRON-1: 52 kg/hr; K-tron-2: 0.5 kg/hr)
MAAG (melt) gear pump speed: 21 rpm, pressure 300 psi
(P3=380 psi, P2=400 psi varied a lot, P3=P2+300 psi)
Die-lip to calibrator distance about 2 in (probably 2.4 in)
Vacuum tank temperature: 14 C (vacuum 1.8 in H2O, appear better 2.5 in H2O)
Spray tank temperature: 18 C
Puller speed: 6 cm/sec then 5.9 cm/sec appears better)
NOTE:
The above are our first ad hock record of experimental testing. Planning and preparation of appropriate forms should be done in advance of experimental extrusion runs.