Eastern Mediterranean University
Department of Mechanical Engineering
Introduction to Capstone Design
MENG 410
Name of Project: REDESIGN
AND
DEVELOPMENT
EXTRUSION MACHINE.
Group Number: 07
Group Members:
143115
ABDELRAHMAN ABOUHANY
143230
HASHEM ALHARTHI
15700444
HUSSAIN SHAWISH
15700833
TARIG MAKKI
Supervisor:
Assis. Prof. Dr. Mohammed Bsher ASMAEL
Semester:
Fall 2018
Submission Date: 14th of December 2018
OF
PLASTIC
ABSTRACT
This report is about redesign and development of plastic extrusion machine that will be capable
of producing continuous plastic filament. Extrusion is a polymer conversion operation in which
a solid thermoplastic material is melted or softened, forced through an extrusion die of the
desired cross-section, and cooled. In order to produce a good quality of the plastic filament
product, the temperature in each zone of the extruder barrel must be properly set and precisely
controlled. The temperature of the plastic extrusion system has a wide range of variation subject
to various disturbances. The system is generally nonlinear and so, controlling the temperature
is a challenging process, as it has multiple stages and the system is coupled with each other.
The aim of this report is to illustrate the design process of the plastic extrusion machine,
including, the design of the driving, controlling, and cooling systems. Also, this report
illustrates the design progress through stages from the formulation of the problem statement to
prototype testing.
The project scope includes all aspect of design and fabrication to create a plastic extrusion
machine that is easy to easy to use, safe, and low cost to facilitate its usability in producing
continuous plastic filaments which are used in 3D printing technology. From here the
significance of the project becomes since it contributes to the success and development of
humankind.
The project objectives are to design for safety, cost, assembly, high performance, less
impact on the environment.
The project constraints are redesign constraints, economic, environmental, availability,
reliability, manufacturability, and safety.
i
TABLE OF CONTENTS
ABSTRACT ............................................................................................................................................. i
LIST OF FIGURES ................................................................................................................................ iv
LIST OF TABLES .................................................................................................................................. v
LIST OF SYMBOLS and ABBREVIATIONS ...................................................................................... vi
CHAPTER 1 - INTRODUCTION .......................................................................................................... 1
1.1.
Detailed definition of the project ............................................................................................. 1
1.2.
Significance of the project ....................................................................................................... 2
1.3.
Detailed project objectives ...................................................................................................... 3
1.3.1 Design for safety .................................................................................................................... 3
1.3.2 Design for cost........................................................................................................................ 3
1.3.3 Design for assembly ............................................................................................................... 3
1.3.4 Design for performance .......................................................................................................... 4
1.3.5 Design for environment .......................................................................................................... 4
1.4.
Detailed project constraints ..................................................................................................... 4
1.5.
Report Organization ................................................................................................................ 5
CHAPTER 2 - LITERATURE REVIEW ............................................................................................... 6
2.1. Background information ............................................................................................................... 6
2.1.1 Polymers ................................................................................................................................. 6
2.2. Concurrent solutions..................................................................................................................... 9
2.3. Comparisons of the concurrent solutions ................................................................................... 11
2.4. Engineering standards of the concurrent solutions ..................................................................... 13
CHAPTER 3 -DESIGN and ANALYSIS ............................................................................................. 14
3.1. Proposed/Selected design ........................................................................................................... 14
3.1.1 Extruder barrel ...................................................................................................................... 14
3.1.2 Extruder screw ...................................................................................................................... 16
3.1.3 Control system ...................................................................................................................... 19
3.1.4 Cooling system ..................................................................................................................... 22
3.1.5 Drive system ......................................................................................................................... 23
3.1.6 Extrusion die......................................................................................................................... 24
3.1.7 Heater bands ......................................................................................................................... 24
3.1.8 Safety emergency stop switches ........................................................................................... 26
3.1.9 Hopper .................................................................................................................................. 28
3.1.10 Table ................................................................................................................................... 28
3.2.
Engineering standards ........................................................................................................... 28
3.3. Design calculations..................................................................................................................... 29
ii
3.3.1 Polymer melt flow rate in the extruder ................................................................................. 29
3.3.2 Drive motor power analysis.................................................................................................. 34
3.3.3 Energy contribution by heater bands .................................................................................... 35
3.4.
Cost analysis .......................................................................................................................... 36
CHAPTER 4 – MANUFACTURING PLAN ....................................................................................... 39
4.1.
Manufacturing process selection ........................................................................................... 39
4.2.
Detailed manufacturing process ............................................................................................ 43
CHAPTER 5 - PRODUCT TESTING PLAN ....................................................................................... 46
5.1.
Verification plan of the objectives of the project .................................................................. 46
5.2.
Verification plan of the applied engineering standards ......................................................... 47
REFERENCES ...................................................................................................................................... 49
APPENDIX A: Electronic Media .......................................................................................................... 50
APPENDIX B: Constraints ................................................................................................................... 51
APPENDIX C: Standards ...................................................................................................................... 52
APPENDIX D: Logbook ....................................................................................................................... 53
APPENDIX E: Project Timeline ........................................................................................................... 54
APPENDIX F: Engineering Drawings .................................................................................................. 55
APPENDIX G: Product Breakdown Structure ...................................................................................... 55
iii
LIST OF FIGURES
Figure 1: Components and features of a single-screw extruder………………………...……….2
Figure 2: Viscosity as a function of temperature for selected polymers………………………...7
Figure 3: Diagram of an injection molding machine……………………………………………9
Figure 4: Injection blow molding: (1) parison is injected molded around a blowing rod; (2)
injection mold is opened and parison is transferred to a blow mold; (3) soft polymer is inflated
to conform to the blow mold; and (4) blow mold is opened, and blown product is
removed…………………………………………………………………………………….....10
Figure 5: Compression molding for thermosetting plastics: (1) charge is loaded; (2) and (3)
charge is compressed and cured; (4) part is ejected and removed……………………………...10
Figure 6: Plastic extrusion machine assembly………………………………………...………14
Figure 7: Universal 1/16 DIN digital PID controller…………………………………………20
Figure 8: Variable frequency drive HY series……………………………………………….22
Figure 9: Emergency stop switch compact model number 61-6441.4047…………………….27
Figure 10: Drag and pressure flow in the metering zone of a single screw extruder. Note: symbol
h here represents screw flight diameter (D)……………………………………........................29
Figure 11: Details of an extruder screw inside the barrel………………………………………30
iv
LIST OF TABLES
Table 1: Thermoplastics properties……………………………………………………..………8
Table 2: Criteria matrix for plastic forming machines selection…………………….………...12
Table 3: Extruder barrel linear material dependence on polymers……………………....……15
Table 4: Extruder barrel design specifications…………………………………….…...……...16
Table 5: Extruder screw design specifications………………………………………….…….18
Table 6: GL 102 temperature controller specifications……………………………………….20
Table 7: Drive motor design specifications……………………………………………...…….23
Table 8: Criteria matrix for heater bands selection…………………………………………...25
Table 9: Heater bands properties……………………………………………………………...25
Table 10: Ceramic insulated heater bands design specifications……………………………...26
Table 11: Extruder design and operating parameters………………………………….………33
Table 12: Capital investment………………………………………………………………….36
Table 13: Other expenses……………………………………………………………………...36
Table 14: Bill of materials…………………………………………………………………….37
Table 15: Criteria matrix for extruder barrel manufacturing method selection……………….39
Table 16: Criteria matrix for extruder screw manufacturing method selection……………….40
Table 17: Criteria matrix for cooling system welding method selection……………………...41
Table 18: Criteria matrix for hopper welding method selection………………………………42
Table 19: Criteria matrix for table welding method selection………………………………...42
Table 20: Project constraints………………………………………………………………….51
Table 21: Logbook…………………………………………………………………………….53
v
LIST OF SYMBOLS and ABBREVIATIONS
3D: Three Dimensional
P: Power
MPa: Mega pascal
p: Pitch diameter
RPM: Revolution per minute
DC: Direct current
AC: Alternating current
MPa: Mega pascal
lb: Pound
Hz: Hertz
V: Voltage
W: Watt
A: Ampere
in: inch
Ra: Reduction area
vi
CHAPTER 1 - INTRODUCTION
1.1. Detailed definition of the project
Engineering design is the process of devising a system, component, or process to meet desired
needs. It is a decision-making process (often iterative), in which the basic sciences,
mathematics, and engineering sciences are applied to convert resources optimally to meet a
stated objective. Plastic extrusion machine design process includes elements of the engineering design
process. The general layout, type of extruder screw, contributes to determining the type of plastic
extrusion machine. There are different types of extruder screws: single-screws, mixing-screws,
twin-screws, and vented screws. For this project, type of screw is standard single-extruder
screw.
A single-screw extruder as shown in Figure 1 consists of a screw in a barrel. One end of the
extruder barrel is attached to the feed throat while the other end is open, and the barrel is
surrounded by heating and elements (ceramic insulated heater bands). A feeding hopper is
located above the feed throat. The screw itself is coupled through a thrust bearing and gearbox
(reducer), to a drive motor that rotates the screw in the barrel. An extrusion solid-round profile
die (orifice) is connected to the open end of the extruder with a breaker plate and screen pack
forming a seal between the extruder and die.
During extrusion, thermoplastic pellets are fed from the hopper, through the feed throat of the
extruder, and into the extruder barrel. The pellets fall onto the rotating screw and are packed in
the feed section of the screw. The packed pellets are melted as they travel through the
compression section of the screw, and the melt is mixed in the metering section. The pressure
generated in the extruder forces the molten polymer through the die. The extruded cross-section
is called extrudate.
1
Figure 1: Components and features of a single-screw extruder (Groover, 2010).
1.2. Significance of the project
Plastics are inexpensive, durable materials, and can be manufactured easily to various types of
products that can be used in many applications. From here, plastic production reached the
highest levels over the last 60 years. Most of the produced plastics are discarded within a short
period from the year of manufacturing. This disposal generates several environmental and
health problems. From here, recycling plastic disposal becomes important. The extrusion
process is the simplest process of recycling and reusing the plastic. This is achieved using a
plastic extrusion machine.
The products that are produced using a plastic extrusion machine are important in a person's
everyday life. Also, plastic extrusion machine products are essential materials that are used in
many applications.
The significance of this project becomes from the ability to design and manufacture a plastic
extrusion machine that is capable of producing a continuous filament with a diameter of 3 (mm)
from various types of discarded thermoplastics such as Polypropylene (PP), Polystyrene (PS),
and Polyethylene terephthalate (PET). The usage of this plastic filament will be for 3D printing
technology, with the intent to make the 3D printing sustainable and economic.
2
1.3. Detailed project objectives
The main goal of this project is to manufacture a single screw plastic extruder which acquires
the capability of producing continuous plastic filaments from various types of thermoplastics.
The detailed project objectives are discussed below.
1.3.1 Design for safety
This design consists of an emergency stop switch. Emergency stop is a function that is intended
to avert harm or to reduce existing hazards to persons, machinery, or work in progress. The
Emergency stop switch when pressed, it will immediately start the emergency stop sequence.
A safety manual is also attached to the table, which states all the rules and precautions when
operating on the machine. A non-conductive safety mat is also installed under the table to
insulate and protect workers from shocks created by high-voltage equipment.
1.3.2 Design for cost
Design for cost is the conscious use of engineering processing technology to reduce the design
cost. The main aim is to enhance the performance of the system while reducing costs, also seeks
to reduce cost as possible while meeting customer demands by the means of using suitable lowcost materials and manufacturing processes. Mechanical fasteners were used to minimize the
use of welding as its cost is much higher than mechanical fasteners, also for the decision
matrices, priority was for the cost.
1.3.3 Design for assembly
DFA is the method of design of the product for ease of assembly. DFA is also a tool used to
assist in the design of products that will transition to productions at a minimum cost, focusing
on the number of parts, handling, and ease of assembly. For this project, the table was
manufactured with supports carrying each of the main components, and mechanical fasteners
were mostly used for assemble instead of a permanent joint to ease the maintenance.
3
1.3.4 Design for performance
High voltage ceramic heater bands enhanced the performance of the machine by heating the
barrel as fast as possible, and to the highest temperatures. Therefore, permitting the machine to
operate using a wider range of thermoplastics. Meanwhile, a high-power motor was branched
as part of this design due to the fact that it generates large amounts of torque, therefore, allowing
the screw to extrude a variety of thermoplastics.
1.3.5 Design for environment
Plastics are organic materials, just like wood, or paper, or wool. In today’s society plastics can
be found everywhere, and they make it possible to balance modern day needs with
environmental concerns. The single screw plastic extruder was designed with the capability of
using recyclable and non- recyclable plastics.
1.4. Detailed project constraints
Project constraints are as follows:
1. Cost: The manufacturing and assembly costs must not exceed the available budget.
2. Reliability: The machine is to be manufactured in such a way that it minimizes the
chances of any failure occurring.
3. Design: The modifications to extruder barrel and screw are limited, due to the fact that
this project is a re-design of last year’s project.
4. Efficiency: The machine is to be manufactured in a form that enables the input to be
converted to the output without any offsets.
5. Maintainability: The extruder is designed in such a way that if any failure occurs, the
machine is to repair quickly and with ease.
4
1.5. Report Organization
The following report consists of five chapters, each chapter divided into different subsections.
The first chapter being the introduction, which entails five sections which are, the detailed
definition of a plastic extrusion machine, the Significance of the plastic extrusion Machine, the
detailed project objectives, the detailed project constraints and finally the structure of the report.
The second chapter, literature review consists of the background of the plastic extrusion
machine and the types of polymers, the other sections consist of the concurrent solutions, which
show the other types of machines used for our same application, the comparisons of these
concurrent solutions and finally the engineering standard used.
The third chapter, design, and analysis consist of the proposed/selected design, which states
why the components that were used were the most compatible to our design. The other sections
include the engineering standards used, design calculations and last of all the cost analysis (bill
of materials).
The fourth chapter, manufacturing processes contain two sections which are manufacturing
processes selection were all the types of manufacturing processes are mentioned and the other
section which is the detailed manufacturing processes were the manufacturing processes
mentioned in the previous sectioned and mentioned in full detail.
The fifth and last chapter, product testing plan which entails the Verification plan of the
objectives of the project as well as the Verification plan of the applied engineering standards.
5
CHAPTER 2 - LITERATURE REVIEW
2.1. Background information
Plastic forming machines were rapidly developed until the 1930s. The first single-screw
extruder for polymers was produced in 1951 in Japan for extrusion of wire/cable coating from
low-density polyethylene. Since then, many kinds of single-screw extruders have been
manufactured and used for example, for fiber-spinning of polyamide and polyester and for filmmaking of poly (vinyl chloride) and polyolefin.
2.1.1 Polymers
A polymer molecule consists of many repeating mers to form very large molecules held together
by covalent bonding. Elements in polymers are usually carbon plus one or more other elements
such as hydrogen, nitrogen, oxygen, and chlorine. Secondary bonding (van der Waals) holds
the molecules together within the aggregate material (intermolecular bonding). Polymers have
either a glassy structure or mixture of glassy and crystalline. Polymer melt viscosities vary from
102 to 106 (Pa-s). An average value for thermoplastics is 102 (Pa-s) as shown in fig. There are
differences among the three polymer types:
1. In thermoplastic polymers, the molecules consist of long chains of mers in a linear
structure. These materials can be heated and cooled without substantially altering their
linear structure.
2. In thermosetting polymers, the molecules transform into a rigid, three-dimensional
structure on cooling from a heated plastic condition. If thermosetting polymers are
reheated, they degrade chemically rather than soften.
3. Elastomers have large molecules with coiled structures. The uncoiling and recoiling of
the molecules when subjected to stress cycles motivate the aggregate material to exhibit
its characteristic elastic behavior.
6
Polymer melt viscosity varies from 102-106 (Pa-s). The average value for thermoplastics is 102
(Pa-s) as shown in Figure 2.
Figure 2: Viscosity as a function of temperature for selected polymers (Groover, 2010).
The selected types of thermoplastics pellets for this project are as follows:
1. Polypropylene (PP): A versatile polymer used in applications from films to fibers with
a worldwide demand of over 21 million pounds.
2. Polystyrene (PS): One of the four plastics whose combined usage accounts for 75% of
the worldwide usage of plastics.
3. Polyethylene terephthalate (PET): the most common thermoplastic polymer resin of the
polyester family and is used in fibers for clothing, containers for liquids and foods,
thermoforming for manufacturing, and in combination with glass fiber for engineering
resins.
4. Low-density polyethylene (LDPE): Combines high impact strength, toughness, and
ductility to make it the material of choice for packaging films, which is one of its largest
applications.
7
5. High-density polyethylene (HDPE): is known for its large strength-to-density ratio. The
density of HDPE can range from 930 to 970 kg/m 3. Although the density of HDPE is
only marginally higher than that of low-density polyethylene, HDPE has little
branching, giving it stronger intermolecular forces and tensile strength than LDPE. The
difference in strength exceeds the difference in density, giving HDPE a higher specific
strength.
Thermoplastics mechanical and physical properties are shown in Table 1.
Table 1: Thermoplastics properties (Harper, 2000).
Plastics
Tm (°C)
Tg (°C)
Td (°C)
Tensile
Compressive
Density
strength
strength
(g/cm3)
(MPa)
(MPa)
Polyethylene
245-265
73-80
21-38
48.3-72.4
75.8-103.4
1.29-1.40
168-175
-20
107-121
31.0-41.4
37.9-55.2
0.900-0.910
74-105
68-96
35.9-51.7
82.7-89.6
1.04-1.05
-25
40-44
8.3-31.4
79-91
22.1-31
terephthalate
Polypropylene
Polystyrene
Low-density
98-115
0.917-0.932
polyethylene
High-density
130-137
18.6-24.8
0.952-0.965
polyethylene
Where,
•
Tm - crystalline melting temperature (some plastics have no crystallinity and are said to
be amorphous).
•
Tg - glass transition temperature (the plastic becomes brittle below this temperature).
•
Td - heat distortion temperature.
8
2.2. Concurrent solutions
There are 5 different types of plastic forming machines:
1. Injection molding machine as shown in Figure 3 uses thermoplastics to produce solid
pieces such as plastic products. The plastic injection molding process produces large
numbers of parts of high quality with great accuracy, very quickly. Plastic material in
the form of granules is melted until soft enough to be injected under pressure to fill a
mold. The result is that the shape is exactly copied.
Figure 3: Diagram of an injection molding machine (Groover, 2010).
2. Extrusion process as shown in Figure 1 which is one of the few molding methods that
can be performed on hot or cold material. The extrusion process is a simple process in
which molten polymer is forced through a shaped die using pressure. The pressure is
generated from the action of screw rotation against the barrel wall.
3. Injection Blow molding as shown in Figure 4, this is used for the production of hollow
glass and plastic objects in large quantities. Material granules for the part is fed via a
hopper into a heated barrel, melted using heater bands and the frictional action of a
reciprocating screw barrel. The plastic is then injection through a nozzle into a mold
cavity where it cools and hardens to the configuration of the cavity.
9
Figure 4: Injection blow molding: (1) parison is injected molded around a blowing rod; (2) injection mold
is opened and parison is transferred to a blow mold; (3) soft polymer is inflated to conform to the blow
mold; and (4) blow mold is opened, and blown product is removed (Groover, 2010).
4. Compression molding as shown in Figure 5, the most common process used with
thermosetting materials and is usually not used for thermoplastics. Compression
molding is the process of molding in which a preheated polymer is placed into an open,
heated mold cavity. The mold is then closed with a top plug and compressed in order to
have the material contact all areas of the mold.
Figure 5: Compression molding for thermosetting plastics: (1) charge is loaded; (2) and (3) charge is
compressed and cured; (4) part is ejected and removed (Groover, 2010).
10
2.3. Comparisons of the concurrent solutions
In this section, all the concurrent solutions mentioned above will be discussed thoroughly with
a decision matrix showing why the chosen solution in each category is the most suitable for the
following application.
Comparisons on the most common plastic processing technology (Extrusion, Injection molding,
and Blow molding):
Injection Molding is a manufacturing process for producing parts in large volume. It is most
typically used in mass-production processes where the same part is being created thousands or
even millions of times in succession. The principal advantage of injection molding is the ability
to scale production in mass. Once the initial costs have been paid the price per unit during
injection molded manufacturing is extremely low. The price also tends to drop drastically as
more parts are produced. Meanwhile, the front costs tend to be very high due to design, testing,
and tooling requirements. If you are going to produce parts in high volumes, you want to make
sure you get the design right the first time. That is more complicated than it might sound. The
two major downsides to injection molding are its high tooling costs and large required lead
times.
The second type being extrusion is used when dealing with products having a consistent crosssection. The advantages offered by the extrusion machine are its low cost, high flexibility and
the capability of post extrusion alteration, however, the disadvantages are as follow; Size
variances in the final product as well as product limitations. The downsides to this process
might be crucial when dealing with mass production, but in our case, they don’t carry that much
importance.
11
The third type which is the blow molding machine, mainly used to make hollow plastic
containers such as bottles, and jars. Milk containers, shampoo, and soda bottles, and watering
cans are examples of products that are typically blow molded. The gains of this process are,
low tooling costs, recyclable products, high production rate, and intricate geometries are
possible. The downside is that the parts manufactured must always be hollow and controlling
wall thickness is difficult.
The criteria matrix shown in Table 2 will illustrate how the decision was taken and state the
factors considered with their importance.
Table 2: Criteria matrix for plastic forming machines selection.
Legend
Priority
Importance Injection
molding
(weight)
Blow
molding
Extrusion
Low cost
1
10
8
10
10
Machinability
2
8
8
6
8
Low Lead
timing
4
4
6
8
8
Flexibility
3
6
6
8
10
High
production rate
5
2
10
6
6
224
240
268
1→ worst
10→ Best
Weighted total
12
2.4. Engineering standards of the concurrent solutions
•
ISO 527: specifies the test conditions for the determination of the tensile properties of
plastic.
•
ASTM D695: Standard test method for compressive properties of rigid plastics.
•
ASTM D618: Standard practice for conditioning plastics for testing.
•
ASTM D790: Standard test methods for flexural properties of unreinforced and
reinforced plastics and electrical insulating materials.
The standards shown above are only some of the plastic standards used. Standards for
plastic are usually categorized into many various groups; the types used for our
application are as follows:
1- Analytical Method.
2- Cellular materials {plastic and elastomers}.
3- Durability of plastic.
4- Environmentally degradable plastics and bio-based products.
5- Thermosetting materials.
6- Thermoplastic materials.
7- Terminology.
13
CHAPTER 3 -DESIGN and ANALYSIS
3.1. Proposed/Selected design
The selected shaping process of polymer for this project is a plastic extrusion machine with a
single extruder screw. Figure 6 shows the plastic extrusion machine configuration, the part
numbering is shown in Appendix G. The design of each part (assembly) will be illustrated in
the following sections.
Figure 6: Plastic extrusion machine assembly.
3.1.1 Extruder barrel
The barrel is a metal cylinder that surrounds the screw. One end fastens to the feed throat and
the opposite end connects directly to the die adapter. Since extruder barrels must withstand
pressures up to 70 (MPa), they are usually made from standard tool steels, with special tool
steels required for corrosive polymers.
14
The internal diameter of the extruder barrel typically ranges from 25 to 150 (mm). The barrel
is long relative to its diameter, with L/D ratios usually between 10 and 30. The higher ratios are
used for thermoplastic materials, whereas lower L/D values are for elastomers. Since melting
occurs over a longer transition zone, longer barrels provide increased output. However, the
longer screws require larger drive systems and produce greater screw deflection.
The clearance between the barrel and screw flights is typically 0.08 to 0.13 (mm). To reduce
barrel wear, barrels are nitrided. Nitriding is the surface hardening of the barrel. This process
initially produces higher hardness but loses that advantage as the barrel wears. Nitriding also
provides poor abrasion and only moderate corrosion resistance. Table 3 shows the dependence
of nitrided alloy steel on the polymer and its additives. Table 4 shows barrel specifications.
Table 3: Extruder barrel linear material dependence on polymers (Harper, 2000).
Nitrided alloy
Resins being processed
Mild
Medium
Severe
Critical
Acetates,
polyethylene
(PE),
steel
polypropylene
(PP),
polyamides,
PVC,
polystyrene (PS), PET
ABS,
polyacetals,
acrylics,
polycarbonates, polyesters, SAN
Resins containing up to 30% glass, mineral, flame-retardant
and other filler material
Good
Satisfactory
Poor
Fluoropolymers, phenolics, resins containing more than Not
30% glass, mineral, flame-retardant and other filler material recommended
15
Table 4: Extruder barrel design specifications.
Barrel length
947 (mm)
Barrel internal diameter (D)
30 (mm)
Barrel (L/D) ratio
L/D = 947/30 = 31.567
Barrel material
Nitrided alloy steel
Barrel material grade
38CrMoAIA
Barrel material tensile strength
0-980 (MPa)
Barrel material yield strength
0-835 (MPa)
Nitrided hardness
950-1050HV
Surface roughness
Ra 0.4 μm
3.1.2 Extruder screw
The material is conveyed through the barrel toward the die opening by the action of the extruder
screw. Extruder screws fit into the barrel and are supported by the thrust bearing. The screw’s
shank length fits into the thrust bearing, while the flighted length contacts the plastic.
The screw (flighted section) serves several functions and is divided into sections that
correspond to these functions. The sections and functions are the (1) feed section, in which the
stock is moved from the hopper port and preheated; (2) transition or compression section, where
the polymer is transformed into liquid consistency, air entrapped amongst the pellets is
extracted from the melt, and the material is compressed; and (3) metering section, in which the
melt is homogenized and sufficient pressure is developed to pump it through the die opening.
16
In metering screws, the feed zone has a constant channel depth as does the metering zone.
However, the channel depth gradually decreases in the transition zone. Since molten polymer
requires less volume than the solid particles, the metering zone channel depth is shallower than
the depth of the feed. The squeezing of the polymer is quantified by the compression ratio CR:
𝐶𝑅 =
𝐻𝑓𝑖𝑟𝑠𝑡 𝑐ℎ𝑎𝑛𝑛𝑒𝑙 6 𝑚𝑚
=
=2
𝐻𝑙𝑎𝑠𝑡 𝑐ℎ𝑎𝑛𝑛𝑒𝑙
3 𝑚𝑚
Equation 1
Where,
H is the channel depth.
Screws are made from good tool-grade steels or stainless steel. They are then treated, coated,
or plated to reduce the coefficient of friction between screw and polymer, improve chemical
resistance, improve abrasion resistance, and reduce wear. Table 5 shows screw specifications.
Pitch (p) is the axial distance from the center of one flight to the center of the next flight,
whereas lead is the axial distance the screw moves in one full rotation. The screw flight angle
A can be calculated as
𝑝
30
𝐴 = tan−1 ( ) = tan−1 (
) = 17.7°
𝜋𝐷
𝜋 × 30
Equation 2
17
Table 5: Extruder screw design specifications.
Screw type
Square-pitched metering screw
Screw overall length (Ls)
971 (mm)
Screw flight diameter (D)
30 (mm)
Screw feed section length
476 (mm)
Screw compression section length
112 (mm)
Screw metering section length
145 (mm)
Screw flight length
733 (mm)
Screw shank length
238 (mm)
Screw flight land width (wf)
0.004 (m)
Screw channel width (wc)
0.0248 (m)
Screw metering zone channel depth (Lm)
3 (mm)
Screw feed section channel depth
6 (mm)
Screw compression ratio CR
2
Screw pitch (p)
30 (mm)
Screw flight angle (A)
17.7°
Screw material
Nitrided alloy steel
Screw material grade
38CrMoAIA
Screw material tensile strength
0-980 (MPa)
Screw material yield strength
0-835 (MPa)
Nitrided hardness
950-1050HV
Linearity of screw
0.015 (mm/m)
18
3.1.3 Control system
Control system for the extrusion machine will include temperature controllers, and drive motor
speed controller.
To accurately control process temperature without extensive operator involvement, a
temperature control system relies upon a controller, which accepts a temperature sensor such
as a thermocouple as input. It compares the actual temperature to the desired control
temperature, or setpoint, and provides an output to a control element.
A temperature Sensor measures the temperature of a location where the temperature control is
required. It converts the temperature to a physical quantity of a voltage or resistance and outputs
that. The selected temperature sensor for this project is thermocouple. A thermocouple is a
temperature sensor that uses a phenomenon (the seebeck effect) that generates a thermoelectromotive force according to the temperature difference between the joint end and the open
end of different types of metal that have been joined together at one end. The combination of
metals with high and stable thermo-electromotive force is called a thermocouple (Ormon
industrial automation, 2018).
Proportional, integral, and derivative (PID) temperature controller is selected for this project.
This controller combines proportional control with two additional adjustments, which helps the
unit automatically compensate for changes in the system. These adjustments, integral and
derivative, are expressed in time-based units. The proportional, integral and derivative terms
must be individually adjusted or "tuned" to a particular system using trial and error. It provides
the most accurate and stable control of the three controller types and is best used in systems
which have a relatively small mass, those which react quickly to changes in the energy added
to the process (Omega engineering inc., 2018).
19
Since temperature controllers are generally mounted inside an instrument panel, the panel must
be cut to accommodate the temperature controller. In order to provide interchangeability
between temperature controllers, most temperature controllers are designed to standard DIN
sizes. The selected PID controller for this project is universal 1/16 DIN digital PID temperature
controller (GL 102 type) as shown in Figure 7. Table 6 shows GL 102 PID temperature
controller specifications.
Figure 7: Universal 1/16 DIN digital PID controller (Golander, 2018).
Table 6: GL 102 temperature controller specifications.
Power supply
AC/DC 85~260V (50Hz/60Hz)
Solid state relay (SSR) control signal
12 V (open-circuit voltage), 30 mA (shortcircuit current)
Temperature accuracy
0.2% Full scale (FS)
Controller dimensions
Height = 48 (mm), width = 48 (mm), length
= 75 (mm)
Mounting panel cutout
Height = 48 (mm), width = 48 (mm)
20
A variable frequency drive (VFD) is a particular kind of adjustable-speed drive that is used to
control the speed of an AC motor. In order to control the motor's rotational speed. VFD
characteristics are as follows (Anaheim automation, inc., 2018):
•
A variable frequency drive controls the frequency of the electrical power supplied to the
motor. When complete voltage is applied to an AC motor, it accelerates the load and
drops torque initially, keeping current especially high until the motor reaches full speed.
•
A variable frequency drive operates differently; it eliminates excessive current,
increasing voltage and frequency in a controlled manner as the motor starts.
•
A variable frequency drive converts power through three different stages. First, AC
power is converted to DC power, followed by the switching on and off of the power
transistors, causing a voltage waveform at the desired frequency. This waveform then
adjusts output voltage according to the preferred designated value.
A variable frequency drive operator interfaces allow the user to adjust operating speed and start
and stop the motor. The operator interface might also allow the user to switch and reverse
between automatic control, or manual speed adjustment. Advantages of a variable frequency
drive are listed below (Anaheim automation, inc., 2018):
1. Process temperature can be controlled without a separate controller.
2. Low maintenance.
3. Longer lifespan for the AC motor and other machinery.
4. Lower operating costs.
5. Equipment in the system that cannot handle excessive torque is protected.
The selected VFD speed controller for this project is HY series, 380 (V), 4 (kW) as shown in
figure.
21
Figure 8: Variable frequency drive HY series (Huanyang electrical co., ltd, 2018).
3.1.4 Cooling system
A cooling system is composed mainly of a water bath through which the extruded shape
(extrudate) travels, hardening as it goes. When it is sufficiently cooled, it is wound on a reel.
The selected cooling system design for this project consists of the following:
1. Water bath made of aluminum 6061, with 1 (m) length, and 0.5 (m) width, and 0.2 (m)
depth.
2. Water bath pulleys with 0.05 (m) diameter.
3. Wind-up unit consisting of:
a. Reel wheel with 0.3 (m) outer diameter.
b. Reel supports.
c. Reel bearings.
d. Wind-up motor.
22
3.1.5 Drive system
Extruder drive motors must turn the screw, minimize the variation in screw speed, permit
variable speed control (typically 50 to 150 rpm), and maintain constant torque. In selecting
drive motors, the three major factors are: (1) base speed variation, (2) the presence or absence
of brushes, and (3) cost. The speed variation of a drive motor is based on the maximum speed
available for the motor. The three basic types of drives are alternating current (AC), direct
current (DC), and hydraulic motors.
The power supply converts three-phase AC line voltage to variable voltage DC power and then
back to controlled AC frequency. Since the voltage-to-frequency ratio is adjusted to provide
constant torque from the ac motor, speed-torque characteristics can be optimized by varying
the voltage-to-frequency ratio. The high-speed drive motor is coupled to the low-speed screw
using a gearbox. Typical reduction ratios are 15:1 or 20:1. Switching to larger gears increases
the torque but reduces the screw speed. Table 7 shows the design specification of the selected
motor for this project.
Table 7: Drive motor design specifications.
Motor type
Alternating current (AC) drive motor
combined with a gearbox
Motor power supply
Three phases
Motor output power required
4000 (W)
Operating frequency
50 (Hz)
Required speed
50 (rpm), 5.236 (rad/s)
Required torque
760 (Joule)
Gear ratio
29:1
23
3.1.6 Extrusion die
The shape of the die orifice determines the cross-sectional shape of the extrudate. The polymer
melt flows into a converging die entrance, the shape designed to maintain laminar flow and
avoid dead spots in the corners that would otherwise be present near the orifice. The die opening
is made long enough to remove some of the memory in the polymer melt. The design
specifications of the selected extrusion die are as following:
1. Die opening diameter Dd = 0.0023 (m)
2. Die opening length Ld = 0.074 (m)
3.1.7 Heater bands
Barrels and dies are heated to bring them to operating temperatures and to maintain set
temperatures during operation. Heater bands are typically used for heating extruder barrels and
dies. Subsequent mixing and mechanical working of the material generate additional heat,
which maintains the melt. There are four types of heater bands used in plastics processing: (1)
mica, (2) aluminum, (3) ceramic, and (4) bronze heater bands. Table 8 shows criteria matrix for
heater bands selection based on cost, maximum produced temperature, performance, produced
energy, and service life.
Ceramic insulated heater band are very energy efficient since they have a standard ¼ inch (6.35
mm) thick insulation. Table 9 shows heater bands properties, where, power density equals total
watts divided by heated area. Table 10 shows the design specification of the selected ceramic
insulated heater bands for this project.
24
Table 8: Criteria matrix for heater bands selection.
Legend:
Priority
1→ worst
Importance
Mica
Aluminum
Ceramic
Bronze
(weight)
10→ best
Cost
1
9
4
3
10
5
2
8
6
7
7
5
temperature
4
6
7
4
9
10
Performance
2
8
7
10
5
10
Service life
3
5
5
6
10
8
207
217
290
265
Energy
efficiency
Maximum
Weighted
total
Table 9: Heater bands properties (Harper, 2000).
Tmax, Co
Power density, kW/m2
Mica
480
85
Aluminum
370
310
Ceramic
~750
35
Bronze
870
310
Heater band
25
Table 10: Ceramic insulated heater bands design specifications.
Ceramic heater band size (90x150)
Ceramic heater band size (90x100)
Voltage
220 (V)
Voltage
220 (V)
Current
6.82 (A)
Current
5.68 (A)
Power
1.5 (kW)
Power
1.25 (kW)
Surface width
150 (mm)
Surface width
100 (mm)
Surface thickness
11.9 (mm)
Surface thickness
11.9 (mm)
External diameter
41.9 (mm)
External diameter
41.9 (mm)
Internal diameter
30 (mm)
Internal diameter
30 (mm)
Cylindrical area (heated
0.0141 (m2)
Cylindrical area (heated
0.00942 (m2)
area)
Cylindrical
area)
0.0942 (m)
circumference
Cylindrical
0.0942 (m)
circumference
3.1.8 Safety emergency stop switches
Emergency stop switches, generally referred to as E-Stops, ensure the safety of persons and
machinery and provide consistent, predictable, failsafe control response. A wide range of
electrical machinery must have these specialized switch controls for emergency shutdown to
meet workplace safety and established international and U.S. regulatory requirements. E-Stops
– critical human machine interface (HMI) devices – differ from simple stop switches (that
merely turn equipment off) in that they offer "foolproof" equipment shutdown. This is
26
accomplished through advanced switch design that requires a twist, pull, or key to release
electrical contacts to allow machinery restart.
According to international standards, the emergency stop function must be initiated by a single
human action using a manually actuated control device. The E-Stop function must be
operational at all times and designed to stop the machine without creating additional hazards.
Actuators should be precision molded from high-quality polymeric materials to assure a
mechanical life in excess of 6,050 operations as required by industry standards, including EN
IEC 60947 5-5.
Resetting the electrical system can only be done by first releasing the E-Stop that was originally
activated. If E-Stops were activated at multiple locations, all must be released before machinery
restart. It should be noted that resetting E-Stops does not in itself restart the machinery; it only
permits restarting through normal procedures appropriate for the machinery involved.
The selected E-Stop design for this project is EAO series 61 emergency stop watch compact,
foolproof (EN IEC 60947-5-5), model number 61-6441.4047 as shown in fig.
Figure 9: Emergency stop switch compact model number 61-6441.4047 (EAO switch corporation, 2018).
27
3.1.9 Hopper
The feed hopper feeds material to the extruder, single-screw extruders are usually fed
gravimetrically through standard conical or rectangular hoppers. The selected design for this
project is rectangular hopper with the following dimensions:
1. Hopper upper rectangular dimensions 180x180 (mm2).
2. Hopper lower rectangular dimensions 52x52 (mm2).
3. Hopper feed opening diameter 80 (mm).
3.1.10 Table
The designed table has L shape with the following dimensions:
1. Table length 3.5 (m).
2. Table width 0.6 (m) divided as:
a. 0.5 (m) for wooden plates.
b. 0.1 (m) for table steel frame.
3. Table height 1 (m).
4. Barrel support height 0.2 (m).
5. The portion of the L shape dimensions are: length as 0.5 (m) and width as 0.6 (m).
3.2. Engineering standards
Standards for designs are as follows:
1.
2.
3.
4.
EN 41 CrAIMo7-10
AIC 62321-1: 2013
EN IEC 60947-5-5
ISO 13850
Screw and barrel nitriding steel standard.
Test standard for heater bands.
Emergency stop switch compact, foolproof.
Emergency stop switch design standard.
28
3.3. Design calculations
In this section, mathematical models are used to describe several aspects of polymer extrusion
analysis. Calculations are to be carried out for determining the following:
1. Polymer melt flow rate in the extruder.
2. Drive motor power analysis.
3. Energy contribution by heater bands.
3.3.1 Polymer melt flow rate in the extruder
The rotating screw pushes material along the walls of the stationary barrel creating drag flow.
This drag flow provides the forward conveying action of the extruder, and, in the absence of a
die, is effectively the only flow present. The addition of a die restricts the open discharge at the
end of an extruder and produces a large pressure gradient along the extruder. Since the pressure
is greatest just before the die, this head pressure creates two other flows, pressure flow Q p and
leakage flow QL. Since they both counter the forward motion of the melt, pressure and leakage
flow are often lumped together as back flow Qb. As shown in Figure 10 drag flow conveys the
polymer along the barrel walls, whereas pressure flow forces the material near the screw back
toward the hopper.
Figure 10: Drag and pressure flow in the metering zone of a single screw extruder (Harper, 2000). Note:
symbol h here represents screw flight diameter (D).
29
A simple mathematical modeling of extrusion assumes that: (1) the extruder is at steady state,
(2) the melt is Newtonian, (3) the extruder is isothermal, and (4) the metering zone make the
only contribution to output, (5) there is minimal leak flow through the clearance between flights
and barrel. Figure 11 shows details of an extruder screw inside the barrel.
Figure 11: Details of an extruder screw inside the barrel (Groover, 2010).
The net output flow rate of the extruder can be expressed as the difference between the drag
flow and back pressure flow as follows:
𝑄𝑥 = 𝑄𝑑 − 𝑄𝑏
Equation 3
Where,
Qx = the resulting flow rate of polymer melt in the extruder (m3/s).
Qd = volume drag flow rate (m3/s).
Qb = back pressure flow (m3/s).
30
𝑄𝑑 = 0.5 𝜋 2 𝐷 2 𝑁 𝑑𝑐 sin 𝐴 cos 𝐴
Equation 4
Where,
D = screw flight diameter (m).
N = screw rotational speed (rev/s).
dc = screw channel depth in the metering zone (m).
A = screw flight angle (degree).
𝑄𝑏 =
𝑝 𝜋 𝐷 𝑑𝑐3 sin2 𝐴
12 𝜂 𝐿𝑚
Equation 5
Where,
p = head pressure in the barrel (MPa).
Lm = length of the metering zone (m).
η = viscosity of polymer melt, N-s/m2 (Pa-s).
If back flow is zero, so that melt flow is unrestrained in the extruder, then the flow would equal
drag flow given by Equation 4. This is the maximum possible flow capacity of the extruder.
Denoted as Qmax:
𝑄𝑚𝑎𝑥 = 0.5 𝜋 2 𝐷2 𝑁 𝑑𝑐 sin 𝐴 cos 𝐴
Equation 6
If back pressure were so great as to cause zero flow, then back pressure flow would equal drag
flow. By equating both expressions for drag and back pressure flows and solving for head
pressure gives the maximum head pressure. Denoted as pmax:
31
𝑝𝑚𝑎𝑥 =
6𝜋 𝐷 𝑁 𝐿𝑚 𝜂 cot 𝐴
𝑑𝑐2
Equation 7
Therefore, the resulting flow rate of polymer melt in the extruder can be rewritten as:
𝑄𝑥 = 𝑄𝑚𝑎𝑥 − (
𝑄𝑚𝑎𝑥
)𝑝
𝑃𝑚𝑎𝑥
Equation 8
Flow rate through the die depends on the size and shape of the opening and the pressure applied
to force the melt through it. Denoted as QDie:
𝑄𝐷𝑖𝑒 = 𝐾𝑠 𝑝
Equation 9
Where,
Ks = shape factor for the die (m5/N-s). For a circular die opening of a given channel length, the
shape factor is:
𝜋 𝐷𝑑4
𝐾𝑠 =
128 𝜂 𝐿𝑑
Equation 10
Where,
Dd = die opening diameter (m).
Ld = die opening length (m).
Above equations contains two types of parameters: (1) design parameters, and (2) operating
parameters. Table 11 shows both design parameters and operating parameters for the extruder
of this project.
32
Table 11: Extruder design and operating parameters.
Design parameters
Operating parameters
Screw flight diameter (extruder barrel internal Screw rotational speed N = 0.833 (rev/s)
diameter) D = 0.03 (m)
Screw metering zone length Lm = 0.145 (m)
Polymer melt viscosity (an average value for
thermoplastics) η = 100 (Pa-s)
Screw metering zone channel depth dc = 0.003
(m)
Flight angle A = 17.7o
-
Screw pitch p = 30 (mm)
-
Flight land width wf = 0.004 (m)
-
Screw channel width wc = 0.0248 (m)
-
Die opening diameter Dd = 0.0023 (m)
-
Die opening length Ld = 0.074 (m)
-
Using the values from Table 11, and substituting in Equation 6:
𝑄𝑚𝑎𝑥 = 0.5 𝜋 2 (0.03)2 (0.833) (0.003) sin(17.7°) cos(17.7°) = 3.215 × 10−6 (
𝑚3
)
𝑠
And, using the values from Table 11, and substituting in Equation 7:
𝑝𝑚𝑎𝑥 =
6𝜋 (0.03) (0.833) (0.145) (100) cot(17.7°)
= 2,377,993.515 (𝑃𝑎) = 2.378 (𝑀𝑃𝑎)
(0.003)2
33
Substituting the values of Qmax and pmax in Equation 8:
𝑄𝑥 = (3.215 × 10−6 ) − (
3.215 × 10−6
) 𝑝 = (3.215 × 10−6 ) − (1.352 × 10−12 )𝑝
2.378 × 106
Using the values from Table 11 and substituting in Equation 10:
𝐾𝑠 =
𝜋 (0.0023)4
𝑚5
= 9.282 × 10−14 (
)
(128) (100) (0.074)
𝑁−𝑠
Substituting the value of Ks in Equation 9:
𝑄𝐷𝑖𝑒 = (9.282 × 10−14 )𝑝
Equating both equations, and solving for p:
(3.215 × 10−6 ) − (1.352 × 10−12 )𝑝 = (9.282 × 10−14 )𝑝 → 𝑝 = 2,225,190.681 (𝑃𝑎)
= 2.22519 (𝑀𝑃𝑎)
Solving for Qx using Equation 8:
𝑄𝑥 = (3.215 × 10−6 ) − (
3.215 × 10−6
𝑚3
6)
−7
(2.22519
×
10
=
2.066
×
10
)
(
)
2.378 × 106
𝑠
𝑚𝑚3
= 206.6 (
)
𝑠
3.3.2 Drive motor power analysis
The drive motor power can be determined by the following equation:
𝑃=𝑁𝑇
Equation 11
Where, P = power (Watt), N = screw speed (rad/s), T = torque (Joule).
Using the values given in Table 7 and substituting in
𝑃 = (5.236)(760) = 3979.36 (𝑊𝑎𝑡𝑡) → 𝑠𝑒𝑙𝑒𝑐𝑡𝑖𝑛𝑔 4 (𝑘𝑊) 𝑚𝑜𝑡𝑜𝑟
34
3.3.3 Energy contribution by heater bands
The energy contribution by each of the heater bands can be calculated by the following
equation:
𝐸=𝑃𝑡
Equation 12
Where,
E = energy (Joule).
P = power (Watt).
t = time (second).
From Table 10 the power values are:
For the first size of heaters (90×150), P1 = 1.5 (kW).
For the second size of heater (90x100), P2 = 1.25(kW).
Using these values and substituting in Equation 12, the energy produced by 1 heater in onehour period is:
𝐸1 = (1500
𝐽𝑜𝑢𝑙𝑒 60𝑠 60𝑚𝑖𝑛
)(
)(
) = 5.4 (𝑀𝐽)𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
𝑠
𝑚𝑖𝑛
ℎ𝑜𝑢𝑟
And, for the second size with P2:
𝐸2 = (1250
𝐽𝑜𝑢𝑙𝑒 60𝑠 60𝑚𝑖𝑛
)(
)(
) = 4.5 (𝑀𝐽)𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
𝑠
𝑚𝑖𝑛
ℎ𝑜𝑢𝑟
Therefore, the total energy produced by four ceramic insulated heater bands (two from each
size) in one-hour period is:
𝐸𝑇 = (2)(5.4) + (2)(4.5) = 19.8 (𝑀𝐽)𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
35
3.4. Cost analysis
Table 12: Capital investment.
Quantity
Unit price
Total
Vernier caliper
1
$20
$20
Gloves
5
$2
$10
Safety glasses
5
$2
$10
Spammer set
1
$10
$10
Hammer
1
$6
$6
Screw drivers set
1
$4
$4
Allen keys set
1
$6
$6
Table 13: Other expenses.
Category
Cost
Food
$150
Transportation
$100
Shipping
$1000
36
Table 14: Bill of materials.
Ite
m#
Part #
Quantit
y
Name
Material
Source
Cost
1
1-1
1 set
Screw and
barrel set
Alloy steel
38CrMoAI
A
Zhoushan Jinmao
Machinery Factory.
$460
Picture
Xihou Industrial Park,
Zhoushan, Zhejiang,
China.
Tel：+86-580-8050975
E-mail
screw@jmjxc.com
2
1-1-4
6
Ceramic
Band
Heaters
Aluminum
and
Ceramic
Yancheng Laiyuan
Electric Equipment
Co., Ltd.
$16
Location: Jiangsu,
China (Mainland)
Tel: +86-15851048592
E-mail: jane@chinalaiyuan.com
3
1-5
25-meter
length
Square cross
section tube
50*50mm
Steel
Paralik CO. LTD
Cyprus Famagusta.
$0.3
per
m
4
1-1-5
1
Steel sheet
750mm*300
mm 1mm
thickness
Steel
Paralik CO. LTD
Cyprus Famagusta.
$10
37
5
1-4-1
1
1-4-2
3 phase AC
motor 4 kw
with gear
box
And Screw
shaft
connection
Various
Zhoushan Jinmao
Machinery Factory.
$100
0
Xihou Industrial Park,
Zhoushan, Zhejiang,
China.
Tel：+86-580-8050975
E-mail
screw@jmjxc.com
Ite
m#
Part #
Quantit
y
Name
Material
Source
Cost
6
1-2-22
2
Temperature
PID
controller
And
Thermocoup
le
Various
Golander LLC.
Duluth, Georgia USA
Tel: 1-678-587-8806
$32
7
1-2-21
1
VFD speed
controller
Various
Huanyang Electrical
Co., Ltd
Taizhou City, Zhejiang
China
$170
8
1-5-2
2 plates
dimensions
2x1.5x0.002
5 (m)
Wood
Paralik CO. LTD
Cyprus Famagusta.
$20
9
1-3-1
and
(0.0051
𝑚3
Aluminum
Alloy 6061
1-3-2
,13.8 kg)
6061
Aluminum
Alloy Sheet
Xinye metal material
CO. Ltd
Shanghai, China.
Tel: +86-21-5661 0102
$3
per
kg
1-2-4
1
Emergency
stop switch
Various
EAO switch
corporation, 98
washington street,
milford CT 06460
Tel: 203 877 4577
$75
10
Picture
38
CHAPTER 4 – MANUFACTURING PLAN
4.1. Manufacturing process selection
For this project the work revolved around adjusting three main systems in such a way that the
design meets the stated goals and objectives, which are the control system, cooling system and
drive system. The manufacturing process of each part (assembly) of the plastic extrusion
machine are as follows:
Extruder barrel: the extruder barrel was manufactured by the means of centrifugal casting. The
barrel was fixed to the barrel stand by the means of mechanical fasteners. The selection matrix
shown in Table 15 illustrates the criteria’s considered when comparing the given manufacturing
methods.
Table 15: Criteria matrix for extruder barrel manufacturing method selection.
Legend
priority
Importance
forging
Centrifugal
casting
1→ worst
10→ Best
strength
3
6
10
10
Reliability
2
8
8
8
Cost effectiveness
1
10
4
10
164
224
Weighted total
Extruder screw: the extruder screw was manufactured using a CNC extruder screw turning
machine and plasma welding as a refurbishment. The extruder screw was attached to the barrel
by the means of insertion with the aid of adhesives.
39
The criteria matrix shown in Table 16 illustrates the criteria’s considered when comparing the
given manufacturing methods.
Table 16: Criteria matrix for extruder screw manufacturing method selection.
Legend
priority
Importance
Automatic
CNC turning
screw machine machine
1→ worst
10→ Best
High precision
1
20
6
10
Cost effectiveness
2
10
8
8
200
280
Weighted total
Control system: the control box was fixed to the table by the means of mechanical fasteners
(bolts, screws, and nuts). The cables and sensors were attached to the table by the means of
insertion.
Drive system motor: the motor was fixed to the table by the means of mechanical fasteners. The
motor and the screw were assembled by the means of insertion. The screw steel shaft connection
was manufactured by the means of vertical extrusion.
Cooling system: the water bath is made up of aluminum 606-T6 sheets. The aluminum sheets
were assembled by the means of gas metal arc welding. The reel was attached to the tank by
the means of mechanical fasteners. Cooling system welding method selection criteria matrix is
shown in Tale 17.
40
Table 17: Criteria matrix for cooling system welding method selection.
Legend
priority
1→ worst
Importance
(weight)
Shielded Arc
Gas metal arc
welding
welding
10→ Best
Better arc time
1
10
8
10
Better torch
2
8
6
8
3
6
6
8
164
212
control
High
deposition
rates
Weighted total
Extrusion die: the orifices die which is made up of H13 tool steel was manufactured by the
means of wire electrical discharge machining (EDM) and drilling. The orifice die was fitted
into the barrel by the means of insertion.
Hopper: the hopper was made out of SAE 4130 Steel sheets that were bent and cut to a certain
extent. The metal sheets were joined by the means of shield metal arc welding. The hopper was
fixed to the barrel by the means of insertion. Welding was chosen as the best alternative, due to
its high strength and reliability, which are vital in terms of avoiding any uncertainties during
the feeding process.
The criteria matrix shown in Table 18 illustrates the criteria’s considered when comparing the
given assembly methods.
41
Table 18: Criteria matrix for hopper welding method selection.
Legend
priority
Importance
1→ worst
Shield metal
Geometric
arc Welding
Fasteners
10→ Best
strength
1
10
10
4
Reliability
2
8
6
8
Cost
3
6
4
8
172
152
Weighted total
Table: The legs and frame are made out of SAE 4130 steel tubes. The top is made out of bench
wood blocks. The steel tubes were assembled by the means of tungsten arc welding; meanwhile,
the upper part was assembled to the lower part by the means of mechanical fasteners. The
criteria matrix shown in Table 19 illustrates the criteria’s considered when comparing the given
assembly methods.
Table 19: Criteria matrix for table welding method selection.
Legend
priority
1→ worst
Importance
(weight)
Gas tungsten
Gas metal arc
Arc welding
welding
10→ Best
Good surface
2
8
8
4
3
6
4
10
188
152
finish
High production
rate
Weighted total
42
4.2. Detailed manufacturing process
Extruder barrel: as mentioned before, the extruder barrel was manufactured using centrifugal
casting. In the centrifugal casting process, molten metal is poured into a preheated, spinning
die. The die may be oriented either on a vertical or horizontal axis depending on the
configuration of the desired part. By spinning a mold while molten metal is poured into it,
centrifugal force acts to distribute the molten metal in the mold at pressures approaching 100
times the force of gravity. The combination of this applied pressure and the engineering
mechanics of controlled solidification and secondary refining produces components of superior
quality. As the die begins to fill, the denser molten metal is forced to the wall of the spinning
die. The directional solidification of sound metal progresses from the O.D. towards the bore,
while the less dense material, including impurities, floats to the I.D. Once the casting has
solidified, the part is removed from the die and residual impurities in the I.D. are machined
away, resulting in a defect-free structure without cavities or gas pockets.
Extruder screw: CNC Turning is a manufacturing process in which bars of material are held in
a chuck and rotated while a tool is fed to the piece to remove material to create the desired
shape. A turret (shown center), with tooling attached is programmed to move to the bar of raw
material and remove material to create the programmed result. This is also called “subtraction
machining” since it involves material removal. If the center has both tuning and milling
capabilities, such as the one above, the rotation can be stopped to allow for milling out of other
shapes. Hard facing process using Plasma transfer arc welding: in plasma spraying, a DC
electric current is used to generate a stream of ionized gas at high temperature. This ionized gas
or plasma is the heat source, which then conducts the coating material, which is introduced into
the plasma stream in the form of a powder onto the extruder screw.
43
Control system: the control box was attached to the table by the means of mechanical fasteners,
which are nuts, bolts, and screws. The holes were drilled using a power drill after all the required
measurements taken. The mechanical fasteners used were certified by ASTM standards. The
wires and sensors where installed by the means of insertion as mentioned above.
Drive system motor: here the only component that was manufactured is the screw shaft
connection, which was manufactured by the means of vertical extrusion. The steel metal blocks
are passed through a die of a circular cross-section by using a mechanical or hydraulic press.
The Mandrel is attached to the end of the ram; hence the clearance between the mandrel and
the die wall determines the tubes wall thickness. Vertical extrusion presses were used rather
than Horizontal due to many factors such as high production rate and uniform deformation due
to uniform cooling of the billet in the container.
Cooling system: The water bath is made up of aluminum 6061-T6 sheets which were joined
together by the means of gas metal arc welding, which is a welding process in which an electric
arc forms between a consumable wire electrode and the aluminum 6061-T6 metal sheets, which
heats the metal sheets, causing them to melt and join. Along with the wire electrode, a shielding
gas feeds through the welding gun, which shields the process from contaminants in the air.
Extrusion die: the die is manufactured by the means of wire Electrical Discharge Machining.
Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to
remove metal by means of electric spark erosion. In this process, an electric spark is used as the
cutting tool to cut (erode) the type H13 tool steel piece to produce the finished part which is the
die.
Heater bands: the heater bands were attached to the barrel by the means of insertion with the
help of clamps and mechanical fasteners such as a nut, bolts, and screws.
44
Hopper: the SAE 4130 Steel sheets were joined using shield metal arc welding. The arc is struck
between the metal rod (electrode) and the steel sheets, both the rod and sheets surface melt to
form a weld pool. Simultaneous melting of the flux coating on the rod will form gas and slag
which protects the weld pool from the surrounding atmosphere. The slag will solidify, and the
cool is chipped off the weld bead as soon as the weld run is complete (or before the next weld
pass is deposited).
Table: the tables frame and legs were made up of SAE 4130 steel ducts as mentioned before.
The frame was manufactured by the means of Gas tungsten arc welding (GTAW), which is an
electric arc welding process was an arc was produced between the non-consumable electrode
and the steel ducts. The weld is shielded from the atmosphere by a shielding gas that forms an
envelope around the weld area. Once the frame was manufactured, the bench wood blocks are
now ready to be installed simply by insertion and with the aid of bolts, nuts, and screws, to
prevent any instability.
45
CHAPTER 5 - PRODUCT TESTING PLAN
5.1. Verification plan of the objectives of the project
Several tests will be conducted to validate the compatibility of the machine to the objectives of
the design and ensure that the requirements and user expectations are met.
•
The Demonstration will be performed to test if the designed height of the table and
components are comfortable for the operator and that the controllers and the emergency
stop switch are within reach when needed, as well as the movement around the machine
is not restricted by the size and shape of the table.
•
The main objective of the machine is to produce a continuous flow of plastic; this will
be verified by allowing the machine to operate continuously for an extended period of
time (a couple of hours) to test its ability in maintaining the continuous flow of the
product without any issues. The main factor to be observed is the melt flow to see if
there is any interruption or discontinuity in the flow, also the motor will be checked to
see if any overheating is generated while the machine is continuously being operated.
•
Due to the fact that the machine is capable of using recyclable plastic as a raw material,
the Ability of the machine to operate smoothly with different feed plastic shapes (pellets,
slices and powder) will be tested by feeding the machine and observing if there is any
alteration in the performance or melt flow when operating with various feed shapes.
•
The product of the machine is a 3D printer filament of 3mm diameter, so the capability
of the machine to produce the desired diameter will to be tested with a Vernier caliper
at several time intervals (to check if there is any time related alterations in the diameter)
and for the different types of plastic.
46
5.2. Verification plan of the applied engineering standards
In order to evaluate whether the machine complies to the design specifications and engineering
standards or not the following teats will be performed:
•
The Verification of the designed polymer melt flow in the extruder will be done by
measuring the volume of the extruded section (extrudate) in one minute (the volume is
calculated for a cylindrical section with length and diameter as the length of the
extrudate in one minute and die orifice diameter).
•
The ability of selected power of the heaters band to supply the desired heating to reach
the melting temperature for the different types of plastics will be tested by setting the
designated melting temperature for the plastic and placing a sample of the raw material
on the barrel surface and observing if melt occurs or not, also the compatibility of the
temperature controller with the heaters band is to be tested for different temperature
ranges. Further testing will be conducted to verify the heater bands performance, the
resistance of the heater band is to be measured using an ohmmeter and the reading will
be compared to the optimal value of resistance in the specifications (or can be easily
calculated by the formula R =
𝑉2
𝑃∗1.065
, where V and P are voltage and power stamped
on the heater band) if the measured value lies within 10 percent of the optimal value
then the heater band is working properly. Similarly, the drawn current by the heater
band is to be measured by an ammeter and the reading will be compared to the optimum
level of current present in the specifications (or can be easily calculated by the formula
𝐼=
𝑃
𝑉
, where V and P are voltage and power stamped on the heater band), if the
measured value lies within 10 percent of the optimum level then the heater band
performance is good.
47
•
The capability of the selected motor to deliver the desired torque and speed (rpm) to the
extruder screw will be verified for the different types of the plastics, in addition the
compatibility of the VFD controller with the motor for different speed ranges.
•
A structural analysis for the table will be conducted on ANSYS software to test the
ability of the design to withstand the applied loads.
•
The Efficiency of the cooling system to cool the product as required will be verified for
the different types of the plastics by physically handling (touching) the product after it
is out of the water bath.
48
REFERENCES
Anaheim automation, inc. (2018). Retrieved December 12, 2018, from AC motor guide:
https://www.anaheimautomation.com/manuals/forms/ac-motor-guide.php
EAO switch corporation. (2018). Retrieved December 12, 2018, from EAO series 61:
http://products.eao.com/index.php?IdTreeGroup=125&IdProduct=68982
Golander. (2018). Retrieved December 12, 2018, from Temperature control:
http://www.golanderusa.com/universal-1-16din-digital-pid-temperature-controller.html
Groover, M. P. (2010). Shapring processes for plastics. In Fundamentals of modern manufacturing (4
ed., pp. 9, 268, 271-278, 287, 296, 297, 299, 300, 301). New York: Wiley.
Harper, C. A. (2000). Processing of thermoplastics. In Modern plastics (pp. 5.24, 5.28, 5.29, 5.42).
McGraw-Hill.
Huanyang electrical co., ltd. (2018). Retrieved December 12, 2018, from Products: Variable
frequency drive: https://huanyangelectrical.en.ec21.com/Products--6878300.html
Omega engineering inc. (2018). Retrieved December 12, 2018, from PID & process temperature
controllers: https://in.omega.com/prodinfo/temperaturecontrollers.html
Ormon industrial automation. (2018). Retrieved December 12, 2018, from Overview of temperature
controllers: https://www.ia.omron.com/support/guide/53/introduction.html
49
APPENDIX A: Electronic Media
Electronic media is media that uses electromechanical devices to access the content. This
section consists of a softcopy of the report, installed on a CD-RW disc, as well as a video
presentation that demonstrates all the work done throughout the project and a fragment showing
how the final product operates. The video is uploaded on the website were more information
can be found on our product.
50
APPENDIX B: Constraints
Table 20: Project constraints.
Constraints
Yes
No
Economic
X
Environmental
X
Reliability
X
Availability
X
Manufacturability
X
Ethical
X
Social
X
Political
X
Health & safety
X
Efficiency
X
51
APPENDIX C: Standards
Standards
Definition
ISO 14001:2004
Environmental management systems
OHSAS 18001;2007
occupational health and safety
ASTM A 450/A 450M
specification for general requirements
for carbon, ferritic alloy, and austenitic
alloy steel tubes
ASTM F467 - 13(2018)
Standard Specification for Nonferrous Nuts
for General Use
ASTM B209 - 14
Standard Specification for Aluminum and
Aluminum-Alloy Sheet and Plate
AMS6348
Standard Specification for steel alloy bars
ISO 9692-3:2016
Standard Specification for Welding and
allied processes
ISO 9692-2:1998
Standard Specification for Submerged arc
welding of steels
ASTM D618
Standard Practice for Conditioning Plastics
for Testing
ISO 527
Specifies the test conditions for the
determination of the tensile properties of
plastic.
AISI H13
Tool steel standard specifications
ANSI/SPI B151.7-2014
Plastics Machinery - Safety Requirements
for Extrusion Machines
EN41CrAIMo7-10
Screw and barrel nitriding steel standards
AIC 62321-1:2013
Test standards for heating elements
EN IEC 60947-5-5
Emergency stop switch compact, foolproof
52
APPENDIX D: Logbook
Table 21: Logbook.
Date
Brief description of the performed work
6/10/2018
Team members meeting to discuss and share idea
about project redesign and development options.
Task was assigned to each member.
10/10/2018
Meeting with the supervisor to propose and discuss
ideas about project redesign and development options.
14/10/2018
Team members meeting to discuss previous-report
summary.
Task was assigned to each team member.
21/10/2018
Team members meeting to discuss tasks assigned on
(14/10).
New task related to report writing was assigned.
24/10/2018
Team members meeting to further discuss tasks
assigned on (14/10) and check the project progress.
29/10/2018
Team members meeting to discuss and share ideas
about tasks assigned on (21/10).
New tasks related to report writing was assigned.
14/11/2018
Meeting with the supervisor to discuss motor
selection decision and project progress.
4/12/2018
Team members meeting to discuss and share ideas
about tasks assigned on (29/10).
5/12/2018
Meeting with the supervisor to discuss project
progress and updates about motor selection.
53
APPENDIX E: Project Timeline
54
APPENDIX F: Engineering Drawings
Drawings starts next page.
APPENDIX G: Product Breakdown Structure
Product breakdown structure starts after engineering drawings.
55
9
8
12
13
7
5
6
1
11
2
10
3
4
INSTRUCTION :
Table frame is welded
NO.
1
2
3
7
8
9
Part name
AC motor
Extruder screw
Extruder barrel
Ceramic heater band
(90x100)
Hopper
Ceramic heater band
(90x150)
Extrusion die
Water bath
Emergency stop switch
10
11
12
13
Wind-up motor
Control box
Reel wheel
Water bath pulley
4
5
6
AC motor is bolted to its stand with 4 bolts
Screw is connected to the AC motor by shaft coupling
Barrel is rested on a semi circular supports and fixed in place with additional holders
Hopper is fixed to the barrel support by 2 bolts
Ceramic heater bands are fixed around the barrel with 2 bolts each
Extrusion die is fastened to the barrel head
Water bath is fixed to the table frame with 4 bolts
Pulleys are fixed to the water bath each with 2 bolts
Reel wheel and bearing are inserted to the reel support
Control box is fixed to the table frame with 4 bolts
Drawn
By:
Checked
By:
Scale:
1:75
NAME
Group 07
Assist. Prof. Dr.
Mohammed
Bsher A. Asmael
SIGN
A.M.A
DATE
12-DEC-18
M.B.A.A 14-DEC-18
Title: Plastic extrusion
machine assembly
Mechanical Engineering
Department
Dimensions are in
milimeters
Tolerance 180-9001
1
2
3
INSTRUCTION :
Barrel head is to be
bolted to barrel by two bolts
No.
1
2
3
Part name
Barrel
Barrel head
Barrel head bolts
NAME
SIGN
DATE
Drawn GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:10
Title:Extruder barrel Part No.:
1-1-1
assembly
Dimensions are in
milimeters
Tolerance 180-9001
1
3
2
INSTRUCTON :
Sliding ring is inserted to the screw tip
Screw tip is fastened to the screw
NO.
Part name
1
2
Screw
Screw tip
Sliding ring valve
(non return valve)
3
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Extruder screw Part No.:
1-1-2
1:10 assembly
Dimensions are in
milimeters
Tolerance 180-9001
80 ±0.01
52
27.26
90 ±0.30
946
NOTE
Material : Alloy steel
38CrMoAIA
80
31
30 ±0.12
90
156
60
75
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:10
Title: Barrel
Part No.:
1-1-1-1
Dimensions are in
milimeters
Tolerance 180-9001
52
43
95
10
30
±0
.1
2
50
90
5
.0
±0
32 ±0.04
12
50
NOTE
Material : Alloy steel
38CrMoAIA
Drawn
By:
Checked
By:
Scale:
1:2
NAME
Group 07
Assist. Prof. Dr.
Mohammed
Bsher A. Asmael
SIGN
A.M.A
DATE
12-DEC-18
M.B.A.A 14-DEC-18
Title: Barrel head Part No.:
1-1-1-2
Mechanical Engineering
Department
Dimensions are in
milimeters
Tolerance 180-9001
M8 Machine Threads
80
10
70
0
5.2
12
10
12
NAME
NOTE
Material : Steel
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:1
Title: Barrel head
bolt
Part No.:
1-1-1-2-1
Dimensions are in
milimeters
Tolerance 180-9001
50
NOTE
Material : Alloy steel
38CrMoAIA
26
R14.
10
24
22.96
30 ±0.03
18
2
4
26
6.05
29
29
55
14
164
733
4
M18 Tapped Hole
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:10
Title: Screw
Part No.:
1-1-2-1
Dimensions are in
milimeters
Tolerance 180-9001
30
25
18
R8
R8
22.60 ±0.20
NOTE
Material : Alloy steel
38CrMoAIA
Drawn
By:
Checked
By:
Scale:
1:2
NAME
GROUP 07
Assist. Prof. Dr.
Mohammed
Bsher A. Asmael
SIGN
A.M.A
DATE
12-DEC-18
M.B.A.A 14-DEC-18
Title: Screw tip
16
12
15
24.02
2.85
22
M8 Machine Threads
22 ±0.02
2.85
16 ±0.02
12.10
5
R1
8.14
135.07
1.57
R2
R2
Part No.:
1-1-2-2
Mechanical Engineering
Department
Dimensions are in
milimeters
Tolerance 180-9001
25
30
23.68
30
NAME
NOTE
Material : Alloy steel
38CrMoAIA
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Sliding ring valve Part No.:
(Non-return valve)
1-1-2-3
3:2
Dimensions are in
milimeters
Tolerance 180-9001
150
114
R57
2
6
R45
NOTE
Material : Aluminum
and ceramic
8
M
4
13.07
NAME
SIGN
70
20
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:5
Title: Ceramic heater
band (90x150)
Part No.:
1-1-4-1
Dimensions are in
milimeters
Tolerance 180-9001
100
114
R57
8
2
99.75
R45
M4
13.07
NAME
NOTE
Material : Aluminum
and ceramic
SIGN
20
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:2.5
Title: Ceramic heater Part No.:
bands(90x100)
1-1-4-2
Dimensions are in
milimeters
Tolerance 180-9001
60
5
2.30
5
5
4
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title:Ceramic heater
bands bolts and nuts
1:1
Part No.:
1-1-4-4
Dimensions are in
milimeters
Tolerance 180-9001
51
60
180
.
84
230
298.49
52
50
20.32
10
10
60
25.50
60
NOTE
Material : Steel
NAME
29.31
SIGN
R4
0
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:6
Title: Hopper
Part No.:
1-1-5
Dimensions are in
milimeters
Tolerance 180-9001
27
3
5
8.70
13.51
11
37
32
M8 Machine Threads
32
NAME
NOTE
Material : Steel
SIGN
DATE
Drawn
Group 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Extrusion die
1:1
Part No.:
1-1-6
Dimensions are in
milimeters
Tolerance 180-9001
15
45
NAME
10
10
6
6
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title:Thermocouples Part No.:
1-2-1
1:1
Dimensions are in
milimeters
Tolerance 180-9001
12
120
255
1000
120
252.50
30
580
40
30
120
250
40
50
255
40
M20x1.5 Tapped Hole
640
NAME
NOTE
Material : Aluminum
alloy 6061 T6
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:20
Title: Water bath
Part No.:
1-3-1
Dimensions are in
milimeters
Tolerance 180-9001
9.68
4.84
7.57
169.95
50
38.70
TRUE R10
8
439.8
NAME
NOTE
Material : Aluminum
alloy 6061 T6
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:5
Title:Water bath pulleys Part No.:
1-3-2
Dimensions are in
milimeters
Tolerance 180-9001
5
30
148
300
300
560
31
300
R1
NAME
NOTE
Material : Aluminum
alloy 6061 T6
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:10
Title: Reel wheel
Part No.:
1-3-3-1
Dimensions are in
milimeters
Tolerance 180-9001
31
74
130
120
130
24
30
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Reel bearing
1:5
Part No.:
1-3-3-2
Dimensions are in
milimeters
Tolerance 180-9001
150
30
100
80
100
5
84.19
100
R15
32
150
100
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Wind-up motor Part No.:
1-3-3-3
1:5
Dimensions are in
milimeters
Tolerance 180-9001
212.17
40
150
412.50
6
40
245
30
16
237.40
245
211.91
65
50
NAME
Drawn By:
Group 07
Checked
By:
Assist. Prof. Dr.
Mohammed
Bsher A. Asmael
Scale:
1:10
SIGN
A.M.A
M.B.A.A
Title: AC motor
DATE
12-DEC-18
Mechanical Engineering
Department
14-DEC-18
Part No.:
1-4-1
Dimensions are in
milimeters
Tolerance 180-9001
10
35
130 55
25
15
356.39
2949.20
549.20
NAME
NOTE :
Material : Steel ASE 4130
SIGN
60
425.40
167.66
200
1038.10
10
50.80
100
250
0
562.50
R4
119.49
662.70
676.20
10
3000
3512.70
10
0
450.80
650.80
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale:
1:50
Title:Table
Part No.:
1-5
Dimensions are in
milimeters
Tolerance 180-9001
360
60
80
510
60
12
40.70
360
300
60
NOTE
50
30
20
10
300
198.25
20
Material : Steel
NAME
SIGN
DATE
Drawn
GROUP 07
A.M.A 12-DEC-18
By:
Prof. Dr.
Mechanical Engineering
Checked Assist.
Mohammed
Department
M.B.A.A 14-DEC-18
Bsher A. Asmael
By:
Scale: Title: Control system Part No.:
1-2
1:10
Dimensions are in
milimeters
Tolerance 180-9001