EXTRUSION DIE DESIGN

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 Introduction

Factors to be understood with relevance to

Processing
Plastics Material Characteristics & Property
Extruder Characteristics
Die Geometry with respect to Product Geometry
Melt fluid flow behaviour along Die Geometry
 Die Swell
 Extruder - Die system characteristics
 Heating System & Temperature Control
 Die strength & Material of construction

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 Chapter 1.
Characteristics & Property of Plastic Materials
Properties of polymers under different physical states obtained
during conversion --
 1st stage - The material is in the solid form, and is converted
to a melt.
 2nd stage - The product shape is obtained from melt
 3rd stage - Stablization by proper forming and cooling.

Properties such as particulate flow melt rheology, thermal

properties, etc. influence the processing operations.

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Die Design

Rheological and Thermal properties of polymer melts are

relevant .

 Thermoplastic resins - Specific grade of thermoplastic resins is

used in the extrusion process.
 Viscosity of melt causes a pressure drop, as the melt flow in the die.
Temperature and shear rate influences viscosity.
 Elastic properties of melt causes additional pressure drop and also
swelling of the extrudate.
Certain thermoplastics are prone to degradation - Smooth melt flow and
temperature controls are essential.
 Melt are likely to corrode the material of construction of the dies.

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PARTICULATE FLOW OF SOLID POLYMERS

(a) Bulk density or bulk factor,

(b) I nter- particle cohesion
(c) Particle-to-metal adhesion

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 RHEOLOGICAL PROPERTIES OF POLYMER MELTS

•Highly viscous - Apparent viscosity’s approaching 106 poises at low strain rates.
•Changing viscosity - It decreases when the velocity of melt flow is increased or
temperature increases or pressure on melt flow is decreased.
•Elasticity - indicate recovery of elastic strain. This is also exhibited by polymer melts in
their ability to generate normal stresses.
•Viscosity under Simple Shear - represented by a relationship known as Power-law
T=k(y)n
•Viscosity under Simple Tension - tensile viscosity () is define as ratio of tensile tress to
tensile rate.  =  / 
•Elasticity under simple shear - due to an elastic stress generated in the normal
direction.Elastic shear modulus (G) =  / .
•Elasticity under simple tension - When the polymer melt is subjected to uniaxial
stretching, a tensile stress is created along with an elastic strain. Usually the modulus
under tension (E) is equal to three times the modulus under shear (G).

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 THERMAL PROPERTIES:

1. Specific Heat
2. Thermal conductivity
3. Thermal diffusivity
4. Diffusivity = Conductivity/(Density x Specific heat)

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 Crystallinity

• Care must be taken in designing dies for crystalline

polymers such as nylon and polyacetal where rapid
volume change takes place during post extrusion
cooling and solidifying, which is apt to create voids in
the central portion of rods. With amorphous polymers
such as polycarbonate and PVC, the change in specific
volume is more gradual and limited.

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 Chapter 2

Extruder Characterises

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 Principles of Extrusion

Screw Extruder Fundamentals:

The function of an extruder -

• Convert a solid polymer feed stock to a homogeneous melt

• Pump it and deliver it at a constant rate and pressure
• Maintain Uniform temperature.

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 Types of Extruders:

1. Single Screw
2.Twin Screw

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 Single Screw Extruder:

Three sections -

– Feed , picks up the solid material from a hopper and conveys it forward
to the transition section.

– Transition, loosely packed material in first compacted and then melted as

it passes through it.

– Metering, Homogenised controlled flow of melt. Special mixing device

are some time is corporate to facilitate melting and homogenization

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 Understanding Output of Extruder
• Q = D  d n h w / 2 - P p h3 / 12 v l

Where
Q= Volume Output
D = Drag factor
P = Pressure factor
d = diameter
n = RPM
h = Channel depth
w = Channel width
p = Pressure
l = distance
v = viscosity
Here Melt is assumed as Newtonian fluid for simplification.

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 MODIFIED SINGLE SCREW EXTRUDERS:

Modifications to improve the performance of the conventional single

screw extruder -

• Devolatizing Extruder
• Feed section modification
• Mixing Device

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 Devolatizing Extruder :

Two approaches to removes volatile from the polymer, which contain

volatile in the form of moisture, solvents, or adsorbed gases.

• 1st method - Avnet port is provided in the barrel wall at the

appropriate position.

• 2nd method - The volatile are extracted through a hole drilled into the
bottom of the screw channel to the hollow core of the screw.

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 Feed section modification:

• The performance of the feed section can improve, by the use of the
special trapped bushes with axial groves fitted inside the feed section
barrel.

• These groves prevent the polymer plug from rotating with screw, so
that the plug is moved forward like a nut held at its circumference, on
a screw rotating inside.

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 Mixing Device :

Mixing devices are incorporated in a conventional single extruder.

• These device help to create a uniform melt of constant temperature and

discharge pressure.

• They are usually adopted especially for large diameter screws and for
high-speed operation.

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 TWIN SCREW EXTRUDER :

• Arrangement of the screws can be divided into two major

categories:

• Non Intermeshing - This configuration can be regarded more or less as

two single screw extruder and should be more appropriately called
double screw extruder. separation between the screw axes is at least
equal to the screw outer diameter.
• Intermeshing - separation between the screw axes is somewhat less
than the outer screw diameter, in the limit the screw surface can be in
mutual contact. According to the screw rotation intermeshing screws
are known as a) contra-rotating and b) co-rotating screws.

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 TWIN SCREW EXTRUSION PROCESS:
Twin screw extruders can be considered as having three sections

• Solid conveying section near the hopper known as feed section,

intermeshing screws can be conveniently represented by two series C-
shaped chambers-one for each screw. It convey the plastic material
positively from hopper to the die by the rotation of the screws.

• Transition section in between, the screw length between the chamber in

which no melt has yet been formed and the chamber in which all the
polymer molten is of the order of one screw diameter.

• Pumping section

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 PUMPING SECTION:

• In the pumping section of the extruder the chambers are filled with the
melt. In a plasticating extruder a change in the length over which the
screws are fully filled with the melt.
• The idealized theoretical volumetric output is given by

Q = 2N Where
• N – revolutions per unit time
• V – chamber volume.

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 TWIN SCREW EXTRUDER CHARACTERISTICS :

• The output Vs head pressure characteristics is completely independent

of operating conditions.
• It is greatly dependent on details of the screw geometry. The size of
the gaps and the pressure gradient are responsible for the reduction in
output at increased head pressures.
• Twin Screw Extruder Characteristic Graph:

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Chapter 3

Die Geometry
&
Types of Die

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 Introduction

Extrusion dies are streamlined flow path to give shape to melt

pumped by the extruder.
Reqiures -
– Abrupt change in cross section should be avoided.
– Avoid stagnation areas in flow path and flow should be smooth.
– Melt should be maintained compact by ensuring sufficient
pressure on melt possibly by path restriction.
– Die construction should be able to withstand internal pressure.
– Die temperature should be maintained.

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 Classification of Dies
According to Extrudate –
i) Solid Extrudate Die – Rod, Sheet, Profile etc.
ii) Hollow Extrudate Die – Pipe, Wire coating etc.

According to Direction of Flow of Melt –

i) Straight through or In line die
ii) Cross Head Dies
iii) Offset Dies

According to the construction -

i) Integer dies
ii) Split dies
iii) Plate dies
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 Design Procedure :

Stages in Die Design Procedure –

•)Understanding Extruder performance regarding Flow Output,

Output Pressure, and linear velocity of melt.
•)Understanding Plastic Material melt Property & Behaviour
•)Understanding Product Shape or Geometry
•)Deciding Flow Profile of Melt in Die.
•)Deciding Minimum Wall Thickness of Die based on Strength of
Material & Actual Dimension Thereof depending upon Assembly
requirement
•)Deciding Heating Load

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 Die Operation :

In extrusion, both the extruder and the Die performance

effects the output of the process. The Diagram below
shows performance of an extruder and a die at given
temperature

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 Die Geometry:

The die channel is made up of two sections

(a) Approach section

(b) Forming section or land section.

Die – Extruder (a) Extruder (b) Die (c) Breaker plate (d) Approach (e) Land

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 Die Geometry :

Approach Section - It is a convergent channel section,

which helps to change the cross section of the extruder to
the desired shape and create a compression of the melt, as
it flows.
• Angle of the convergent section 30 to 90 included
angles.
• For viscous melts such as acrylic or polycarbonate, the
angle may be reduced.
• For small size rods the angle should be reduced.
• For heat sensitive materials the approach should be fully
streamlined to avoid stagnation and consequent
degradation.

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 Die Geometry :

Die Land Design - The land section has the cross-

section of the desired product, and is there fore, the most vital
section of the die.
• The major pressure drop takes place along the land, thus
achieving the desired metering effect.
• Properties of the product usually improve with increased land
length and compression ratios.
• Back pressure must be within stipulated range and frictional
heat must be controlled.
• The aim is to allow the material to relax in the land, before
leaving the die.
• Land orifice should be over size because tension is needed to
pull the extrudate away from the die, resulting in a draw down
of the cross-section.
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 Types of Dies :

1) Rod Die
2) Pipe Die
3) Profile Die
4) Blown Film Die
5) Cast Film / Sheet Die
6) Parison Die
4) Wire & Cable Coating Die

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 Rod Die :
It consists of an approach section with a taper of 60° to 90°
included angle.

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 Pipe Die :

• Pipe is basically a hollow and symmetric

section.
• Different types of Die -
a) In line or straight through Die
b) Offset type

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 IN-LINE OR STRAIGHT -THROUGH DIES

Pipe Die (a) Head (b) Mandrel (c) Spider (d) Die Bush
(e) Die Ring (f) Screw (g) Air Inlet
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 Offset Pipe Die

(a) Die Head (b) Adapter (c) Mandrel (d) Die bush (e) Die
Ring
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Co Extrusion Pipe Die

Co Extrusion Pipe Die: (a) Adapter (b) Head (c) Hollow Mandrel (d) Die Bush
(e) Ring (f) Spider (g) Mandrel

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 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
section is another problem.

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 Profile Die

Curvature in Die for Rectangular and T Section

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 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).

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 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
and helps to adjust radially the die gap or
orifice.
• 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.

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 Side fed dies

(a) Body
(b) Mandrel
(c) Adapter
(d) Die Bush
(e) Die Ring
(f) Centering screw

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 Centre fed dies (Bottom fed dies)

• Melt flow is turned through 90° by an adapter

before it enters the die proper.
• The axial flow path prior to the spider should
be sufficiently long.
• 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.

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 Centre fed dies (Bottom fed dies)

•
(a)Body
(b) Mandrel
(c) Spider
(d) Die Bush
(e) Centering screw
(f) Die Ring

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 Die Gap and Land
•To obtain accurate concentricity of the die orifice or gap
at the land portion either movable mandrel and/or by the
• bush is used.
die

•A series of screw around the circumference of the bush

are positioned for adjustment effected by distorting of the
die bush.

•The die gap is usually between 0.5-2 mm,

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

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 ROTATING TUBULAR DIE

• (a)Body
(b) Mandrel
(c) Spider
(d) Gear
(e) Motor
(f) Slip Ring
(g) Adapter
(h) Seal

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SPREADER PLATE DIE

(a)Body
(b) Mandrel
(c) Inlet port
(d) Bush
(e) Screws
(f) Air Inlet

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 FLAT FILM AND SHEET DIES

Classification of Dies
Fishtail die
Manifold T die
Coat-hanger die

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 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
section are made progressively greater.

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 FISHTAIL DIE

(a) Die Body (b) Adjustable lip (c) Lip clamping screw
(d) Lip adjusting screw (e) Clamping screw

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 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
suitable gap
– The manifold cross-section are of tear-drop or a flat sided
tear-drop shape.
– 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.

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MANIFOLD T-DIE:

(a) Die Body

(b) Manifold
(c) Adjusting lip
(d) Clamping screw

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 COAT-HANGER DIE

– The manifold is sloping at an angle to the flow direction of

the feed, and has therefore the shape of a coat-hanger.
– The manifold cross-section gradually decreases from the
central feed to the side of the die.

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 COAT-HANGER DIE

(a) Die Body (b) Manifold (c)

Fixed jaw (d) Movable jaw (e)
choker bar (f) Clamping screw
(g) Jaw adjustment screw

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 WIRE AND CABLE COATING DIES

• Used for coating metallic wires or cables with a

concentric layer of plastic material formed by the
process of extrusion.
• These are cross head Dies
• Two type of arrangement are commonly used
a) Pressure die
b) Tubing die.

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 PRESSURE DIE

• The coating on wire takes place with in the die with

the melt under pressure , the melt flow surrounding
the wire which leaves the die fully coated.
• The melt pressure produce a tight insulation or
sheath which fills any spaces between conductor or
those between insulated cores and produce a
uniform circular surface
• The radial clearance between the wire and the guide
bush must be small i.e., between 0.025 and 0.05 mm,
to prevent the plastic melt entering the guide bush
and obstructing the easy movement of wire.

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 PRESSURE DIE

(a) Screw extruder (b) Adapter (c) Guide bush

(d) Wire (e) Coated cable

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 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.
– The thickness of the guide bush should be as small as
possible to reduce the drawdown to a minimum.

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 TUBING DIE

(a) Die body (b) Guide bush

(c) Wire

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 PARISON 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

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 Wall thickness controls

Die relaxation zone is convergent taper on the bush to relax to

provide a fully developed profile.
The land section is either parallel, convergent (tulip shape) or
divergent (trumpet shape).
The two conical land sections are necessary for the regulation
of wall thickness of the parison during extrusion.
(a) Parallel Land Section
(b) Conical Land Sections
i) The convergent land section (tulip section).
ii) The divergent land section (trumpet section)

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 PARISON AND DIE SIZING

Parison diameter D
D = S Dm 2L / Π
Where D – parison diameter
Dm – mean diameter
S- die swell ratio for the polymer
L- pinch-off length
Π - 22/7

Die gap in the land section t = W / CΠ Dm L S2

Where t – Die gap (annulus gap)
W – Weight of moulding including flash
Dm – Mean diameter
L- Pinch-off length
S- Die swell ratio for the polymer
C- Constant (0.78)
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Die Construction

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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.
• 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.

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 HEATING SYSTEM AND
TEMPERATURE CONTROL

• All dies require a heating system to maintain a constrain temperature of the melt
during its passage through the die.

• Types of Heater
• Standard Resistance Heater
• Low voltage Resistance Heater
• Induction Heater

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 DESIGN OF ELECTRIC HEATRES

• 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.

• 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 determined.

• Secondly, the amount of heat necessary to maintain the operating temperature

is also determined.

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

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EASE OF MAINTENANCE AND CLEANING

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

and flashing are not uncommon.
• 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 streamlined.
• All corners should have a radius, polyvinyl chloride components have a
tendency to plate out, which forms deposits on the die channels.
• Appropriate temperature at decompression zones help to reduce plate out.
• Flashing is the leakage of melt due to clearance between components.
• The die has to be cleaned often to be removing such material, so as to avoid
material degradation and blemishes on the extrudate surface.
• It should be possible to remove material deposits without dismantling the
entire die.

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 FABRICATION

• The fabrication techniques may be classified into two groups:

• A) Techniques adopted to give approximate shape to the material – such methods

are casting, forging, rolling, extrusion, drawing, stamping and welding.

• B)Techniques adopted to impart the final precise dimension and to ensure the
desired surface finish-such methods are sawing, planing, shaping, turning, milling,
drilling, honing, polishing, electroplating, coating, etc.

• The first group of fabrication techniques is mainly used for fabrication of standard
products, such as rods, sheets, plate, section, billets, wires, etc. these products are
available in all metals, both ferrous and non-ferrous. As far as possible, theses
products cut to appropriate sizes are therefore made use of in die fabrication work.

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 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.

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