Rod Die : Pipe Die :

It consists of an approach section with a taper of 60° to

90° included angle. • Pipe is basically a hollow and symmetric
section.
• Different types of Die -
a) In line or straight through Die
b) Offset type

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

IN-LINE OR STRAIGHT -THROUGH DIES

Offset Pipe Die

Pipe Die (a) Head (b) Mandrel (c) Spider (d) Die Bush
(a) Die Head (b) Adapter (c) Mandrel (d) Die bush
(e) Die Ring (f) Screw (g) Air Inlet
(e) Die Ring
CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

Co Extrusion Pipe Die

Profile Die

In profile section may have varying thickness along the

cross section . The cross section be divided into number
of sub section depending on its area and shape. Different
orifice section needs different land . Longer land give
better finish but more pressure drop.
Non uniform swelling of extrudate from Rectangular and T
Co Extrusion Pipe Die: (a) Adapter (b) Head (c) Hollow Mandrel (d) Die section is another problem.
Bush (e) Ring (f) Spider (g) Mandrel

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

 Profile Die DIES FOR FILMS (Blown Films):
Types of Blown Film Dies

• Dies for tubular blown film can be classified

as:

– (1) Side fed dies(also known as cross head

type) and
– (2) centre fed dies (when the film is blown
vertically upwards, this type is termed as
bottom fed).
Curvature in Die for Rectangular and T Section

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

Side fed dies

Side fed dies

• The hollow die body is vertical with the

centrally located mandrel fixed to lower side.
• The adjustable die bush is located at the top (a) Body
(b) Mandrel
and helps to adjust radially the die gap or (c) Adapter
(d) Die Bush
orifice. (e) Die Ring
(f) Centering screw
• The melt from the extruder flows through the
adapter in a horizontal direction and turns
through 90° in Die, either in the upward or
downward direction.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

Centre fed dies (Bottom fed dies) Centre fed dies (Bottom fed dies)

• Melt flow is turned through 90° by an adapter •

before it enters the die proper. (a)Body
(b) Mandrel
• The axial flow path prior to the spider should (c) Spider
(d) Die Bush
be sufficiently long. (e) Centering screw
(f) Die Ring
• The melt passes through the passages of the
spider and further in a annular gap.
• The mandrel is either supported along the
circumference by the spider or bolted down
around the base.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

 Die Gap and Land ROTATING TUBULAR DIE
•To obtain accurate concentricity of the die orifice or gap
at the land portion either movable mandrel and/or by the
•die bush is used. • (a)Body
(b) Mandrel
•A series of screw around the circumference of the bush (c) Spider
are positioned for adjustment effected by distorting of the (d) Gear
(e) Motor
die bush. (f) Slip Ring
(g) Adapter
•The die gap is usually between 0.5-2 mm, (h) Seal

•Film thickness =
(Die gap * swelling ratio) / ( Blow ratio * Drawdown ratio )

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

SPREADER PLATE DIE FLAT FILM AND SHEET DIES

(a)Body
(b) Mandrel Classification of Dies
(c) Inlet port
(d) Bush Fishtail die
(e) Screws
(f) Air Inlet Manifold T die
Coat-hanger die

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

MANIFOLD T-DIE:

MANIFOLD T-DIE

– The melt from the extruder is fed at the center of the die by
an adapter attached to the extruder.
– Damper section is in the form of a rectangular section, of
(a) Die Body
suitable gap
(b) Manifold
– The manifold cross-section are of tear-drop or a flat sided (c) Adjusting lip
tear-drop shape. (d) Clamping screw
– At end of the damper section a groove is provided extending
over the entire die width and a metal bar matching the
groove shape is placed in the groove. This is known as a
choker bar.It is used as a means of regulating the thickness
of the sheet.
– The last portion of the die forms the lip section, with a gap
smaller than the gap of the damper section.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

 FISHTAIL DIE FISHTAIL DIE

– This type of die is used for extrusion of sheets of

limited width or strips up to 150 mm Width.
– The melt supplied at the centre of die flows
radially over an arc subtended by an appropriate
angle.
– The flow path cross-section can be made slightly
curved, with decreasing section towards the two
sides.
– The gap of the lip section is determined by the
sheet thickness
– The gaps of the damper section and fishtail
(a) Die Body (b) Adjustable lip (c) Lip clamping screw
section are made progressively greater. (d) Lip adjusting screw (e) Clamping screw

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

COAT-HANGER DIE COAT-HANGER DIE

– The manifold is sloping at an angle to the flow direction of (a) Die Body (b) Manifold
the feed, and has therefore the shape of a coat-hanger.
(c) Fixed jaw (d) Movable jaw
– The manifold cross-section gradually decreases from the
central feed to the side of the die. (e) choker bar (f) Clamping
screw (g) Jaw adjustment
screw

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

PRESSURE DIE
WIRE AND CABLE COATING DIES
• The coating on wire takes place with in the die with
the melt under pressure , the melt flow surrounding
• Used for coating metallic wires or cables with a the wire which leaves the die fully coated.
concentric layer of plastic material formed by the • The melt pressure produce a tight insulation or
sheath which fills any spaces between conductor or
process of extrusion.
those between insulated cores and produce a
• These are cross head Dies uniform circular surface
• Two type of arrangement are commonly used • The radial clearance between the wire and the guide
a) Pressure die bush must be small i.e., between 0.025 and 0.05 mm,
to prevent the plastic melt entering the guide bush
b) Tubing die.
and obstructing the easy movement of wire.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

 PRESSURE DIE TUBING DIE

– A thin walled tube of plastic material is extruded

around the guide bush, without any contact with the
wire of cable.
– Tube is drawn or shrink on the wire immediately
outside the die.
– A partial vacuum is produced in the tube to assist the
shrinkage.
– Tubing dies are commonly used for jacketing cables
or coating very thin wires with viscous melts.
– Ratio of area of the melt flow annulus channel
forming the tube to the cross-sectional area of the
final plastic coating is known as drawdown ratio.
(a) Screw extruder (b) Adapter (c) Guide bush
(d) Wire (e) Coated cable
– The thickness of the guide bush should be as small
as possible to reduce the drawdown to a minimum.
CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

PARISON DIE
TUBING DIE
•Use to form Parison in Extrusion Blow Moulding process.
• The Dies for parison are cross head dies.

•Classified as per flow of melt from Extruder to the die.

•They are:
•a)Axial flow head Die .
•b) Radial Flow cross head Die
(a) Die body (b) Guide bush
(c) Wire

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

PARISON AND DIE SIZING

Parison diameter D
Wall thickness controls
Where D – parison diameter
Die relaxation zone is convergent taper on the bush to relax to
Dm – mean diameter
provide a fully developed profile.
S- die swell ratio for the polymer
The land section is either parallel, convergent (tulip shape) or
L- pinch-off length
divergent (trumpet shape).
- 22/7
The two conical land sections are necessary for the regulation
of wall thickness of the parison during extrusion. 2
Die gap in the land section t
(a) Parallel Land Section
Where t – Die gap (annulus gap)
(b) Conical Land Sections
W – Weight of moulding including flash
i) The convergent land section (tulip section).
Dm – Mean diameter
ii) The divergent land section (trumpet section)
L- Pinch-off length
S- Die swell ratio for the polymer
C- Constant (0.78)
CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING
 MATERIALS OF CONSTRUCTION
• Required property - high strength, good hardenability,
resistance to corrosion and must accept pit-free polish. Easy
machinability.
• The most common die - alloy steel.
Die Construction
• These are
I) Nickel-Chromium steel
ii) Nickel-Chromium-Molybdenum steel
iii) High Carbon high Chromium steels.

• Stainless steels, with high carbon and high Nickel-Chromium

content have excellent corrosion resistance properties.

• Hard chromium plating or nickel plating of the flow path surface

gives a high degrees of surface finish.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

HEATING SYSTEM AND DESIGN OF ELECTRIC HEATRES

TEMPERATURE CONTROL
• Electric heater for dies are in the shape of a strip, clamp or cartridge,
their capacities are based on watt density, which is the wattage per unit
area.
• All dies require a heating system to maintain a constrain temperature of the
melt during its passage through the die.
• To assess the capacity of heaters for a die, the amount of heat for
bringing the die to the operating temperature in the required time is first
• Types of Heater
determined.
• Standard Resistance Heater
• Low voltage Resistance Heater
• Secondly, the amount of heat necessary to maintain the operating
• Induction Heater temperature is also determined.

• Whichever of the two is large will decide the heater size.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

FABRICATION
EASE OF MAINTENANCE AND
CLEANING • The fabrication techniques may be classified into two groups:

• During working of dies accumulation of material in certain channel and

plate and flashing are not uncommon. • A) Techniques adopted to give approximate shape to the material – such
methods are casting, forging, rolling, extrusion, drawing, stamping and
• Accumulation of material can avoided if the flow path of the melt is free
and smooth. Any abstraction in the flow in the flow path should be welding.
streamlined.
• All corners should have a radius, polyvinyl chloride components have a • B)Techniques adopted to impart the final precise dimension and to ensure
tendency to plate out, which forms deposits on the die channels. the desired surface finish-such methods are sawing, planing, shaping,
• Appropriate temperature at decompression zones help to reduce plate turning, milling, drilling, honing, polishing, electroplating, coating, etc.
out.
• Flashing is the leakage of melt due to clearance between components.
• The first group of fabrication techniques is mainly used for fabrication of
• The die has to be cleaned often to be removing such material, so as to standard products, such as rods, sheets, plate, section, billets, wires, etc.
avoid material degradation and blemishes on the extrudate surface.
these products are available in all metals, both ferrous and non-ferrous. As
• It should be possible to remove material deposits without dismantling far as possible, theses products cut to appropriate sizes are therefore made
the entire die.
use of in die fabrication work.

CORPORATE TRAINING AND PLANNING CORPORATE TRAINING AND PLANNING

 COST ESTIMATES
• The die is expected to work over long periods giving very large product
output.

• The cost of the die is therefore not a major consideration in design

certain amount of saving may be feasible by proper choice of materials
cost of fabrications can be reduced by material which are easy for
fabrication.

• An estimate of cost of fabrication can be based on the material cost

multiplied by a factor ranging from 1.5 to 10 depending on the extent of
machining and finishing.

CORPORATE TRAINING AND PLANNING