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ZHOUSHAN XINLU PLASTICS MACHINERY CO., LTD.
Zhoushan Xinlu is a professional OEM & OD of screw and barrels for extrusion and injection molding machines who provide high-quality & competitive burst-sales single and twin screw barrel economically and efficiently for nearly16 years!
At present,we produce high-quality series screw and barrel products such as filmblow, waste recycling granulation, extrusion pipe,plate, super-large parallel twin screw conical twin screw, micro-medical instrument screw barrel, food processing screw, and so on, which have received many favorable comments.
We must deal with and solve the various needs of clients in terms of quality, price,delivery time and after-sales service to seek for long-term partners. XINLU welcome to cooperate with you!
LATESTT NEWS
- Clean the screw rod regularly
The extruder screw shall be cleaned regularly to remove dirt, residues and stains
from the surface to reduce the degree of wear. Cleaning methods can generally be
used in mechanical cleaning and chemical cleaning in two ways. Mechanical cleaning
is suitable for relatively clean dirt and residues, can use screw cleaning machine and
wipe; chemical cleaning is suitable for dirt and residue, can use screw cleaning agent
and other cleaning agent.
- Check the screw wear condition regularly
In the long-term use process, the surface will be wear and corrosion, which will
affect the production efficiency and product quality of the extruder. The wear of the
screw should be checked regularly. If the surface of the screw is rough or deformed,
the new screw should be replaced in time.
- Lubricate the screw rod
During the use of the extruder screw, sufficient lubrication should be maintained to
reduce the wear degree and effectively extend the service life. Usually use
calcium-based lubricant, polymeric ester lubricant, liquid wax and other methods for
lubrication.
- Clean up the feeding outlets and residues regularly
In the working process of the extruder screw, part of the raw materials will remain in
the feed port and residues. These residues will affect the working efficiency and
product quality of the extruder. The feeding port and residues should be cleaned
regularly to ensure the normal work of the extruder.
- Maintain the screw and motor regularly
Extruder screw and motor are the main components of extruder. The running
condition of screw and motor should be checked regularly, such as bearing, gear,
belt and other components, and timely adjustment or replacement.
If it occurs in the reducer, it may be caused by bearing damage or poor lubrication, or by gear wear, improper installation adjustment or poor engagement. It can be solved by replacing bearings, improving lubrication, replacing gear or adjusting the gear engagement condition.
If the noise is a sharp scraping sound, the position deviation of the cylinder should be considered to cause the possibility of scraping the shaft head and the transmission shaft sleeve. It can be solved by adjusting the machine barrel.
(3) If the engine cylinder makes noise, it may be the screw bending and sweeping the chamber or the set temperature is too low, resulting in excessive friction of solid particles. It can be handled by straightening the screw or raising the set temperature.
Abnormal vibration
If this situation happens in the reducer, it is caused by the wear of bearing and gear, can replace the bearing or gear to solve; if it occurs in the barrel, it is due to the hard foreign material mixed in the material, need to check the material cleaning situation.
Ring plugging material at the entrance of the screw rod
This fault is mainly caused by the cut-off or insufficient flow rate of cooling water. It is necessary to check the cooling system and adjust the flow rate and pressure of cooling water to the specified requirements.
- Clean the screw rod regularly
The extruder screw shall be cleaned regularly to remove dirt, residues and stains
from the surface to reduce the degree of wear. Cleaning methods can generally be
used in mechanical cleaning and chemical cleaning in two ways. Mechanical cleaning
is suitable for relatively clean dirt and residues, can use screw cleaning machine and
wipe; chemical cleaning is suitable for dirt and residue, can use screw cleaning agent
and other cleaning agent.
- Check the screw wear condition regularly
In the long-term use process, the surface will be wear and corrosion, which will
affect the production efficiency and product quality of the extruder. The wear of the
screw should be checked regularly. If the surface of the screw is rough or deformed,
the new screw should be replaced in time.
- Lubricate the screw rod
During the use of the extruder screw, sufficient lubrication should be maintained to
reduce the wear degree and effectively extend the service life. Usually use
calcium-based lubricant, polymeric ester lubricant, liquid wax and other methods for
lubrication.
- Clean up the feeding outlets and residues regularly
In the working process of the extruder screw, part of the raw materials will remain in
the feed port and residues. These residues will affect the working efficiency and
product quality of the extruder. The feeding port and residues should be cleaned
regularly to ensure the normal work of the extruder.
- Maintain the screw and motor regularly
Extruder screw and motor are the main components of extruder. The running
condition of screw and motor should be checked regularly, such as bearing, gear,
belt and other components, and timely adjustment or replacement.
- 长径比：通常选择较大的长径比，一般在 30 到 36 之间。较长的长径比可以提供更充分的塑化和混合时间，使材料在高速挤出过程中均匀塑化，从而保证管材的质量。
- 螺杆槽深度：螺杆槽深度需要根据管道输出量和物料特性进行设计。一般来说，对于高速挤出机，螺杆槽深度相对较浅，以提高物料输送能力并减少物料在螺杆槽内的停留时间。较浅的螺杆槽可以使物料在螺杆旋转过程中更快地向前推进，从而提高挤出速度。
- 压缩比：压缩比一般在3到5之间。合适的压缩比有助于压实材料，去除材料中的空气，并提高材料的密度和塑化性能。对于高速挤出，压缩比的设计应考虑到材料能够在短时间内完成压缩和塑化过程。
- 螺距：较大的螺距设计有利于提高物料的输送速度，减少物料在螺杆上的滑移，从而实现高速挤出。通常采用等螺距变深或变螺距变深螺距设计，并根据物料特性和螺杆不同截面的加工要求进行优化。
- 螺杆头部结构：螺杆头部通常设计成流线型，例如鱼雷头形状，以减少头部材料的滞留和堆积，避免材料过热或分解。这种结构还可以使材料在挤压过程中分布更均匀，从而提高管材质量。
- 材料选择：由于螺杆在高速挤压过程中承受着高压和摩擦，因此需要选择高强度、耐磨性和耐腐蚀性强的材料，如38CrMoAlA氮化钢，以确保螺杆的使用寿命和稳定性。
- 冷却和润滑：为防止螺杆高速旋转过程中因摩擦生热导致物料过热，需要设计良好的冷却系统。通常，在螺杆内部设置冷却通道，并通入冷却水进行冷却。同时，合理的润滑措施也有助于减少螺杆与料筒之间的摩擦，提高传动效率。
Repair of the barrel
The inner surface hardness of the barrel is higher than that of the screw, and its damage comes later than that of the screw. The scrap of the barrel is the increase of the inner diameter due to time wear. Its repair method is as follows:
1, due to wear to increase the diameter of the barrel, if there is a certain nitriding layer, the barrel hole can be directly boring, grinding to a new diameter size, and then prepare a new screw according to this diameter.
2. The inner diameter of the barrel is machined and trimmed, and the alloy is cast again, the thickness is between 1~2mm, and then finished to the size.
3, under normal circumstances, the homogenization section of the barrel wear faster, this section (take 5~7D length) can be boring and trimmed, and then equipped with a nitriding alloy steel bushing, the diameter of the inner hole is referred to the diameter of the screw, left in the normal matching gap, processing and preparation.
It is emphasized here that the two important parts of the screw and the barrel, one is a slender threaded rod, and the other is a small and long hole in diameter, their machining and heat treatment processes are more complex, and the guarantee of accuracy is more difficult. Therefore, whether to repair or replace the new parts after wear of these two parts must be comprehensively analyzed from an economic point of view. If the repair cost is lower than the cost of replacing the new screw, it is decided to repair, this is not necessarily the right choice, and the comparison between the repair cost and the renewal cost is only one aspect. In addition, it also depends on the ratio of the repair cost and the time of using the screw after repair to the renewal cost and the use time of updating the screw. It is the right choice to adopt the scheme with small ratio only economically.
Conical twin screw extruder and wear failure repair methods extruder wear failure after depending on the screw and barrel wear degree and repair symptoms can adopt the following methods:
- by measuring the screw and barrel of wear in 0.30 Within the mm range, the screw and barrel can be chrome-plated and then finely ground and polished by a dedicated grinding machine to meet the original fit size indicators.
(2) when the barrel when the wear and tear of the available special machine tools will be broaching machine barrel, the other processing a cylinder liner, take hot pressing method and the original barrel set set as a whole, and then according to the size of cylinder diameter (usually slightly smaller than the original barrel diameter size), finishing the other new screw, make it to suit the new cylinder diameter.
(3) update the screw and barrel. It is best to purchase from the original extruder manufacturer to prevent the newly purchased screw and barrel from not matching the electric heating ring, bracket and spline sleeve of the original extruder. Of course, for the general extruder user enterprises, the above-mentioned repair methods require certain mechanical processing equipment and capabilities. The vast majority of enterprises do not have these capabilities and need to contact professional extruder equipment manufacturing enterprises to entrust the repair.
引自-韦永斌.影响锥形双螺杆挤出机磨损的因素及延缓磨损的对策[J].技术与市场,2011,18(11):41-44.
