Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlThis lesson looks at die and calibration tools for making pipes, profiles, and sheets. It explains flow distribution, mandrels, land length, swell control, and vacuum sizing, showing how tool design affects accurate sizes and smooth surfaces.
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 extruderThis lesson reviews haul-off and downstream pulling equipment like belt and caterpillar units. It covers traction control, nip pressure, and matching speed with the extruder to keep product sizes and surface quality steady.
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 systemsThis lesson examines cooling and sizing gear used after the die, such as water baths, spray cooling, and vacuum calibrators. It discusses heat removal rates, size control, internal stresses, and how cooling affects bending or warping.
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 zonesThis lesson details screw design elements and how they affect melting, mixing, and pressure build-up. It covers screw sizes, L/D ratio, flight shapes, compression and metering areas, and tips for picking screws for different plastics and production 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 measurementThis lesson covers main measurement tools in extrusion, like melt and die pressure sensors, barrel temperature checks, and flow meters. It stresses where to place sensors, how to calibrate them, read data, and how signals trigger alarms, safety locks, 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 controlThis lesson focuses on hopper design and handling materials, including drying, moving, and feeding. It compares weight-based and volume-based systems, stresses controlling moisture and dirt, and shares best ways to avoid clogs and uneven mixing.
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 basicsThis lesson explores systems for feeding additives and colours, comparing volume and weight designs. It covers side feeding to twin screws, masterbatch dosing, pigment mixing quality, and ways to stop separation and colour marks.
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 applicationsThis lesson compares single-screw and twin-screw extruders, explaining how they work, melting and mixing, and how choices affect output speed, energy use, and fit for mixing compounds, recycling, or making profiles and films.
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 profilesThis lesson describes cutting and finishing units for extruded items, including flying saws and cold cutters. It explains matching line speed, controlling burrs and dust, size accuracy, and trimming profiles 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 pumpThis lesson identifies key mechanical and heating parts of an extruder. It explains barrel zones, feed throat, screw, gearbox, heaters, temperature sensors, and melt pump, and how design and upkeep affect steady output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
