Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlExplores die and calibration tools for pipes, profiles, and sheets. Covers flow balance, mandrels, land length, swell management, and vacuum sizing, relating tool design to precise dimensions and smooth surface finish.
Pipe, profile, and sheet die typesFlow distribution and manifoldsMandrels, pins, and spider supportsDie land length and swell controlVacuum sizing plates and sleevesLesson 2Haul-off and downstream: belt pullers, caterpillar haul-off, speed synchronization with extruderExamines haul-off and downstream pulling gear, such as belt and caterpillar types. Discusses grip control, pressure settings, and speed matching with the extruder to ensure steady product size and quality surface.
Belt pullers vs caterpillar haul-offSpeed synchronization with extruderNip pressure and slip preventionEffect on wall thickness and ovalityIntegration with downstream cuttersLesson 3Cooling and sizing equipment: water cooling baths, spray rings, cooling tanks, calibrators, vacuum sizing systemsReviews cooling and sizing tools post-die, like water baths, spray systems, and vacuum calibrators. Addresses heat extraction, size control, stress buildup, and cooling effects on bending or distortion.
Water baths and spray ring designCooling tanks and residence timeCalibrators for profiles and sheetsVacuum sizing for pipes and profilesCooling rate, stress, and warpageLesson 4Screw geometry and selection: screw diameter ranges, L/D ratio, flights, compression and metering zonesOutlines screw design features and their role in melting, blending, and pressure build-up. Includes size ranges, L/D ratios, flight patterns, zone types, and tips for choosing screws for various plastics and rates.
Screw diameter and L/D ratio effectsFeed, transition, and metering zonesFlight depth, pitch, and channel volumeBarrier and mixing section optionsScrew selection for materials and outputLesson 5Instrumentation and gauges: melt pressure transducers, die pressure, barrel temperature sensors, flow meters, infrared profile measurementDetails main sensors for extrusion, covering melt and die pressure, barrel heat sensing, and flow tracking. Stresses positioning, calibration, data reading, and integration with alerts and automatic controls.
Melt and die pressure transducersBarrel temperature sensors and placementFlow meters and mass flow monitoringInfrared profile and surface temperatureCalibration, drift, and signal filteringLesson 6Hopper and material handling: dryers, feeders, gravimetric vs volumetric dosing, contamination controlCovers hopper setup and material flow, including drying, transport, and feeding. Compares weight-based and volume-based systems, stresses moisture and dirt prevention, and shares tips to avoid clogs and separation.
Hopper design, liners, and bridgingDryers and moisture specification limitsPneumatic and mechanical conveyingGravimetric vs volumetric dosingContamination and metal detectionLesson 7Additive and color feeding systems: side feeders, loss-in-weight feeders, masterbatch feeders, pigment dispersion basicsReviews systems for adding extras and colours, comparing volume and weight feeders. Discusses side feeding for dual screws, colour dosing, pigment mixing, and ways to prevent separation and streaks.
Volumetric vs loss-in-weight feedersSide feeders for fillers and regrindMasterbatch feeders and color dosingPigment dispersion and streak controlRefill systems and material segregationLesson 8Types of extruders: single-screw vs twin-screw — principles, advantages, typical applicationsContrasts single and twin screw machines, covering work principles, melting and mixing, and how designs affect speed, power use, and fit for mixing, reuse, or shape and film making.
Single-screw operating principle and meltingTwin-screw co-rotating vs counter-rotatingDistributive and dispersive mixing behaviorTypical applications and material suitabilityEnergy efficiency and throughput comparisonLesson 9Cutting and finishing: flying saws, cold cutters, trimming units for profilesDescribes cutting and finishing for extruded items, like moving saws and cold knives. Covers speed matching, edge cleanup, size accuracy, and profile trimming to final specs.
Flying saws for continuous profilesCold cutters for pipes and tubesCut length control and tolerancesBurr, dust, and chip managementEnd finishing and chamfer optionsLesson 10Extruder main components: barrel zones, feed throat, screw, gearbox, heaters, thermocouples, melt pumpIdentifies core parts of extruders, both mechanical and heat-related. Explains barrel sections, feed entry, screw, drive box, heaters, temp sensors, and melt pump, plus upkeep for steady output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
