Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlDis one cover die and calibration tools for pipes, profiles, and sheets. E go talk about flow distribution, mandrels, land length, swell control, and vacuum sizing, showing how design affect size accuracy and 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 extruderE go review haul-off and downstream pulling equipment like belt and caterpillar units. E explain traction control, nip pressure, and how to sync speed with extruder for steady product size and good 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 systemsDis go look at cooling and sizing equipment after di die, like water baths, spray cooling, and vacuum calibrators. E discuss heat removal, size control, internal stress, and how cooling affect warpage.
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 zonesE go detail screw shape and how to choose am, affecting melting, mixing, and pressure. Cover diameter, L/D ratio, flight design, compression and metering zones, plus tips for different plastics and output.
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 measurementDis cover main instruments like melt and die pressure, barrel temp sensors, flow meters. E stress sensor placement, calibration, data reading, and how dem feed alarms and 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 controlFocus on hopper design and handling materials, including drying, conveying, dosing. Compare gravimetric and volumetric, stress moisture and dirt control, and best ways to avoid bridging and mixing up.
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 basicsExplore feeders for additives and color, comparing volumetric and gravimetric. Talk side feeding to twin-screws, masterbatch dosing, pigment mixing, and ways to stop segregation 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 applicationsCompare single-screw and twin-screw extruders, explain how dem work, melting and mixing, and how design affect speed, energy, and use for mixing, recycling, profiles or film.
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 profilesDescribe cutting and finishing for extruded products, like flying saws and cold cutters. Explain sync with line speed, burr control, size accuracy, and trimming profiles to spec.
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 pumpIdentify main parts of extruder like barrel zones, feed throat, screw, gearbox, heaters, thermocouples, melt pump, and how design and care affect steady output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
