Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlDis cover die and calibration tooling for pipes, profiles, and sheets. E go discuss flow distribution, mandrels, land length, swell control, and vacuum sizing, linking tooling design to dimensional 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 extruderDis review haul-off and downstream pulling equipment, including belt and caterpillar units. E go explain traction control, nip pressure, and speed synchronization wid di extruder to maintain product dimensions and surface quality.
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 examine cooling and sizing equipment wey dem dey use after di die, like water baths, spray cooling, and vacuum calibrators. E go discuss heat removal rates, dimensional control, internal stresses, and di impact of cooling profiles on 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 zonesDis detail screw geometry elements and how dem dey influence melting, mixing, and pressure generation. E cover diameter, L/D ratio, flight design, compression and metering zones, and guidelines for selecting screws for different polymers and outputs.
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 key extrusion instrumentation, including melt and die pressure, barrel temperature sensing, and flow measurement. E emphasize sensor placement, calibration, data interpretation, and how signals dey feed alarms, interlocks, and closed-loop control.
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 controlDis focus on hopper design and material handling, including drying, conveying, and dosing. E compare gravimetric and volumetric systems, highlight moisture and contamination control, and review best practices for avoiding bridging and segregation.
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 basicsDis explore feeding systems for additives and colorants, comparing volumetric and gravimetric designs. E address side feeding to twin-screws, masterbatch dosing, pigment dispersion quality, and strategies to avoid segregation and color 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 applicationsDis compare single-screw and twin-screw extruders, explaining operating principles, melting and mixing behavior, and how design choices dey influence throughput, energy use, and suitability for compounding, recycling, and profile or film extrusion.
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 profilesDis describe cutting and finishing units for extruded products, including flying saws and cold cutters. E explain synchronization wid line speed, burr and dust control, dimensional accuracy, and trimming of profiles to meet final specifications.
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 pumpDis identify di main mechanical and thermal components of an extruder. E explain barrel zones, feed throat, screw, gearbox, heaters, thermocouples, and melt pump, and how their design and maintenance dey affect stability and output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
