WOLAITA SODO UNIVERSITY

COLLEGE: - ENGINEERING

DEPARTMENT: - MECHANICAL ENGINEERIN

TOOLS, JIGS & DIE DESIGN

GROUP PROJECT (G-1)

DEFECTS DURING INJECTION & EXTRUSSION BLOW MOLDING,

NAME ID NO
 Table of Contents

Contents Page NO

Abstract........................................................................................................................II

1. DEFECTS DURING INJECTION & EXTRUSSION BLOW MOLDING,

WAYS HOW TO ENCOUNTER THOSE DEFECTS & METHODS OF

ANALYSIS OF EXTRUSION....................................................................................1

1.1 Introduction to blow moulding.............................................................................1

1.2 Types of blow moulding.........................................................................................2

1.3 Defects during injection and extrusion blow moulding......................................3

1.3.1 Defects in Extrusion blow moulding Process....................................................3

1.3.1.1 Ways to encounter extrusion blow moulding defects....................................9

1.3.2 Defects in Injection blow moulding Process...................................................10

1.3.2.1 The ways for Avoiding Injection Blow Moulding Defects..........................10

1.4 Comprehensive common problems with blow moulding products.............18

1.5 Methods of analysis extrusion.............................................................................25

1.5.1 Test method for analysing extrusion defects using RPA 2000......................25

1.5.2 Upper bound solution.......................................................................................26

Reference.....................................................................................................................29

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 Abstract

Present work proposes about both injection and extrusion blow moulding defects, the ways

how to encounter those defects and methods of analysis of extrusion. Blow moulding is a

process used to manufacture plastic products. The process may be injection, extrusion, or

stretch blow moulding. This work over viewed injection and extrusion mouldings with their

basic differences, defects of extrusion blow moulding; improper system engineering

installation, mall function, resin defects, surging, poor mixing, wrong material addition, melt

toughness, overheating, moisture release, trapped air, etc. were explained. Injection blow

moulding defects: Flash, Flow Lines, Warping, Discoloration (Burn Marks), Air pockets,

Weld Line, Vacuum Voids, Sink Marks, Surface Delamination, and Short Shots were

explained briefly. Remedies for those problems were also addressed. Finally methods of

analysis of extrusion; test method using test instrument RPA 2000, & upper bound solution

methods were overviewed.

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1. DEFECTS DURING INJECTION & EXTRUSSION BLOW
MOLDING, WAYS HOW TO ENCOUNTER THOSE DEFECTS &
METHODS OF ANALYSIS OF EXTRUSION

1.1 Introduction to blow moulding

Blow moulding is a process used to manufacture plastic products. The process begins with

melting down the plastic and forming it into a parison, The parison is a tube-like piece of

plastic with a hole in one end through which compressed air can pass.

The parison is then clamped into a mould and air is blown into it. The air pressure then

pushes the plastic out to match the mould. Once the plastic has cooled and hardened, the

mould opens up and the part is ejected, using compressed air to inflate the molten plastic like

a balloon so that it takes the shape of the mould but is hollow inside. The amount of plastic

used and the air pressure determines how thick the final product is.

Blow moulding has its roots in glass blowing, where a craftsman would heat the glass to its

melting point and then blow through a tube to inflate the glass. Blow moulding has been

around since as far back as the 1800s. A patent from the time shows the process of blow

moulding being used with celluloid polymer. These early methods were not suited for mass

production.

In the 1930s, they developed commercial machines to manufacture blow moulded bottles and

made mass production possible. The materials available were too brittle and took too long to

produce to effectively utilize the process to make large quantities.

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Blow moulding exploded into industrial prevalence with the creation of low and high-density
polyethylene. This revolutionized many industries including the soft drink bottling industry
and the automotive industry.

1.2 Types of blow moulding

blow moulding. In Extrusion Blow Moulding (EBM), plastic is melted and extruded into a

hollow tube (a parison). This parison is then captured by closing it into a cooled metal mould.

Air is then blown into the parison, inflating it into the shape of the hollow bottle, container, or

part. After the plastic has cooled sufficiently, the mould is opened and the part is ejected.

In the injection blow moulding (IBM) process, the polymer is injection moulded onto a core

pin; then the core pin is rotated to a blow moulding station to be inflated and cooled. This is

the least-used of the three blow moulding processes, and is typically used to make small

medical and single serve bottles. The process is divided into three steps: injection, blowing

and ejection.

The two moulding processes differs each other in the following criteria the first difference

lies in the type of product which is produced by the respective processes. The extrusion blow

Moulding process creates a two-dimensional product whereas the injection blow Moulding

process creates a three-dimensional product as the final output. The second difference lies in

the tool that is used in both the processes. For the former, a die is used to get the final output

whereas the latter employs the use of a mould. The third difference is in the time taken to

produce the final output with the two processes. The extrusion Moulding process is slower

whereas the Injection Moulding process is faster. The kind of scrap or residue that remains

behind makes for the fourth difference between the two processes. With the former, the scrap

is with flash and trimming whereas, in case of latter, the scrap is without flash and trimming.

The fifth difference is with regard to the part thickness of the machine used in both the

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processes. In case of extrusion, the part thickness depends on how much the material can be

stretched during the process whereas, in case of intrusion, it depends upon the relationship

between the core and the mould.

Extrusion Moulding is regarded as a pocket-friendly process when compared to injection

Moulding. However, the quality of materials that are used varies from extremely poor to

excellent. Styrene is a very poor material that is often used in this process. High-density

polyethylene (HDPE) is excellent whereas polypropylene (PP) and polycarbonate (PC) are

just moderately good for use in the extrusion process.

The quality of all the four materials namely Styrene, PP, PC, and HDPE are excellent in the

injection process. Hence it is a comparatively costly process.

1.3 Defects during injection and extrusion blow moulding

1.3.1 Defects in Extrusion blow moulding Process

To ensure successful extrusion manufacturing, every parameter must be identified,

controlled, and monitored. As the extrusion process studied and improved universally, still it

is having some problems. Defect is any form of deviation of the product’s characteristic from

the specification set up by the manufacturing process. It can be caused by a single source or

the cumulative effect of several factors, which may arise at any stage of the processing. The

common failure or defects which are normally occurring in plastic extrusion process are due

to three main causes: mould design, material selection, and processing. In many cases, the

failures occur during the processing and these failures causes some defects that can be found

in extruded parts such as: rough surface, extruder surging, thickness variation, uneven wall

thickness, diameter variation, centring problem. In extrusion products, defects due to

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processing include, poor understanding of the processing method, use of inadequate or old

machines, lack of trained staff, machine break down, and inappropriate working

environments.

The common defects in extrusion process are:

1. Improper System Engineering/Installation

 Wrong Clamps used or Clamps too tight,

 Improper die setting,

 Improper alignment of die and, Incompatible fire caulk used

 Contact of outside of pipe with incompatible material (e.g., solder flux).

Remedies: Die setting may be adjusted; Checking of alignment, Die heating uniformity

should be checked

2. Improper Operation/ mall function

 Exposure to freezing temperatures without freeze protection

 Over pressurization

 Pulsating water pressure

Remedies: Digital Pressure gauge should be used; proper and Digital temperature sensor

should be used

3. Resin Defects

 Occlusions, char particles, voids

 Filler/pigment not well distributed

 Improper mixing of resin and additives

 Foreign contamination

 Due to over heating

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 Remedies: The resign material screening, Resin material (Mixing percentage) is not exact

4. Improper Materials Addition,

Some of the many problems that can occur during extrusion are traceable to the processed

raw material; that is, the raw material is not up to specification. Regardless of any quality

assurances by manufacturers of raw materials and countless programs such as ISO 9000,

reengineering, plastic batches and even bags or boxes within batches have their

characteristics. With all extrusion parameters the same, the tubing or sheet will have a

different look, bend, colour, or texture. While this may sound unscientific or preposterous,

these problems do occur on the floor. Despite all the computer programs and hardware

designed to keep the quality constant, there will be variations.

Some materials such as polyurethane, nylon, EVOH and others, are hygroscopic (they absorb

moisture from the air). This moisture is undesirable and can cause bubbles in the melt and, in

the case of EVOH, can decrease barrier properties. For this reason, the polymer should be

kept sealed in nitrogen-purged bags whenever possible. However, some plastics can absorb

critical amounts of moisture in the time it takes to open a bag and put it in the hopper. The

material must be dried, preferably in a hopper dryer designed for this purpose.

Other problems include contamination with foreign materials such as metal chips, screws,

bolts, nuts, cardboard, rodents, and rodent droppings. Even so-called medical grade plastics

are often contaminated. Of course, the contaminate will end up in the melt, so every

precaution must be taken to avoid contamination by closing bags, covering hoppers, keeping

a clean area around the extruders, and similar measures.

Remedies: Addition of (mixing percentage) resin material should be exact, Foreign material

should be checked, RPM back pressure should be increased for better mixing

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 5. Surging,

Surging is a cyclical product thickness variation in the direction of extrusion. The surge cycle

time is typically between 30 seconds and 3 minutes, and the cause can be inside or outside the

extruder. Outside causes are easier to see and correct. For example, the take-off pull may be

irregular; in this case the screw rpm and ammeter readings remain steady. Sometimes screw

motor speed varies because its regulation is not working properly. This is rare and will show

up as unsteady rpm. Sometimes the feed is uneven because of particle size, light weight, or

bridging in the hopper and throat. With very small extruders, the feed channel depth is not

much bigger than the feed particles, and they may feed erratically for this reason alone. If

none of these outside causes are observed, it is probable that the surging originates inside,

typically at the beginning of the compression zone, where the solid bed the mass of pellets

may be locking and breaking up irregularly. Screw rpm is steady but the ammeter shows

variations of ± 5% or more. Sometimes this can be cured by increasing the temperature of the

feed to promote earlier melting. Raising the rear barrel temperature may help, too. Make big

changes, 25-50 °F (14-28 °C), and see what happens. Sometimes raising the barrel

Temperature at the beginning of the compression zone will help by getting better sticking of

the pellets to the wall there.

Remedies: Try to running the extruder slower or faster by at least 10%, Altering or replacing

the screw, installing a gear pump between the extruder and the die.

6. Poor mixing,

Poor mixing often sets the upper limit for output. The screw cannot be run any faster because

the material is coming out with an “applesauce” surface, with streaks, parabolic ridges, and

perhaps Particles of undispersed additive. Screw modifications, such as pins or separate

mixing heads will help, but may raise melt temperature. Running more slowly will always

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help, as it provides more residence time. A screw with internal cooling mixes better because

it has the effect of a shallower channel in the metering zone. The output per rpm drops 30, but

may be regained by increasing the screw speed, unless melt temperature gets too high or the

drive system cannot safely run faster. High pressure is good for mixing. A valve will do this,

or a gear pump pressure control that can serve as a valve. Cooler dies increase the resistance

and thus raise the pressure in the system. Finer screens will raise the pressure, but as they

keep clogging, pressure is inconsistent.

Remedies: Exact addition of (Percentage of mixing) resin material, Check for foreign

material, Increase rpm back pressure for better mixing.

7. Melt toughness or melt fracture,

This refers to fine ridges or rough surface seen when the melt comes too fast out of a narrow

die. It is most common with polyethylene, and can be eliminated by running the melt or the

die lips hotter, using a longer or more streamlined die, or trying a different grade or source of

material. Additives may help greatly in this regard.

Remedies: Use the Correct additive; maintain the speed of extruder, Trying a different grade

or source of material.

8. Overheating

Overheating may limit the rate if the take-off cooling is limited, or it may produce

degradation or make dimensional control and sizing difficult. In such a case, stop all barrel

heat except in the rear zone as needed for bite (input) control and cool the barrel if necessary.

(In a few cases, more barrel heat will yield a cooler melt.) There is a temperature below

which the melt will not go at a given screw speed, even if all the barrel heaters are turned

off. See if the controller around 70% down the barrel is overriding. This means over packing

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of the metering zone overbite with much heat generated at the entry to that zone. In that case,

reduce the bite by changing the feed temperature, rear barrel temperature, or particle size.

Remedies: Stop all barrel heat except in the rear zone as needed for bite (input) control and

cool the barrel if necessary.

9. Moisture release

Moisture is absorbed by some plastics. It passes through the extruder and boils when the

pressure is relieved at the die lips. The result is a pattern of dotted lines, long bubbles, and

pits. To remove moisture, the material must be pre-dry, or a vent must be used in the

extruder, or both. A moisture level of 0.1% is usually low enough to avoid such visual

problems. Some plastics, such as PET, the nylons, and polycarbonate, can degrade and

weaken if even a tiny amount of moisture is present when they are melted. For these,

dehumidifying dryers are used to get moisture down to 0.01% or less.

Remedies: To remove moisture, the material must be pre-dry, Vent must be used in the

extruder, and Keep the moisture level of 0.1% is usually.

10. Trapped air

This is not common in pelletized material used with long extruder barrels. However, some

old machines have short barrels, and even a long machine can be pushed so fast that the air is

carried forward into the product. A trapped-air surface shows bubbles and pits, but little, if

any, dotted lines. Such a surface will improve if run more slowly if moisture is not the

problem. Cooler head and die may help. Vents and vacuum hoppers will eliminate trapped

air and are essential for powders, where passages between the particles are much smaller.

Remedies: Avoid the over-speed of extrusion, Pre-Dry the material, Vents and vacuum

hoppers will eliminate trapped air.

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1.3.1.1 Ways to encounter extrusion blow moulding defects

Guide lines for resolving some of the more common problems of extrusion moulding in the

running time of extrusion blow moulding machines;

 Oval Necks and Rocker Bottoms- An oval-shaped neck and rounded bottoms that

rock is the result of warpage. Usually, uneven or inadequate cooling of the blown

product before removing it from the mould is the cause. For this, increase the flow. If

a high stock temperature is the cause, drop it down in small increments to see if that

helps.

 Wall Defects- Another problem has to do with defects in the wall of the extruded

product. When operating an extrusion blow moulding machine, make sure there’s no

moisture in the melt. For this issue, be sure the resin warms up and that any moisture

evaporates before going into the extruder.

 Cold Spots- When running extrusion blow moulding machines, cold spots can

sometimes appear on the wall of the blown object as non-homogeneous areas.

Typically, insufficient back pressure is the reason. Another potential cause is non-

uniformity in the melt.

 Weld Thinning- When this occurs, the most common culprit is a stock temperature

that’s too high. What happens is that as the moulds close, making the pinch-off, the

process doesn’t force enough material into the weld line. As a result, there’s a weak

weld. In this case, you can slowly reduce the stock temperature on the extrusion blow

moulding machine. If that doesn’t help, try adjusting the length of the pinch-off land.

 Tearing- People who operate extrusion blow moulding machines also deal with

tearing problems. There are several possible causes for this. First, the length of the

pinch-off land is too long. Therefore, you would need to shorten it. Another

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 possibility is a worn pinch-off. The resolution for this is to either roll it back

temporarily or refurbish it.

 Poor Surface- If the bottle surface has pits, there’s a good chance you’re working

with an imperfect parison. However, a subpar mould surface could also be the

problem. If that’s the issue, you’ll need to refinish them. The goal is to create a matte

finish. That way, air can vent quickly, allowing the parison to conform to the surface

while the mould’s still hot.

1.3.2 Defects in Injection blow moulding Process

The defects are: Flash, Flow Lines, Warping, Discoloration (Burn Marks), Air pockets, Weld

Line, Vacuum Voids, Sink Marks, Surface Delamination, and Short Shots.

1.3.2.1 The ways for Avoiding Injection Blow Moulding Defects

1. Flash

Flash is a moulding defect that occurs when some molten plastic escapes from the mould

cavity. Typical routes for escape are through the parting line or ejector pin locations. This

extrusion cools and remains attached to the finished product. It is a small flap of thin plastic

material that remains on the edges of a finished product. Typically, this occurs when the

material ends up on the outside of the mould where it solidifies. This defect compromises

aesthetics.

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Image No 1.0 Flash formation from Paulsontraining.com

Remedies: Increase the clamp pressure to ensure that the mould parts remain shut during

shots, Ensure that the mould is properly maintained and cleaned (or replaced when it has

reached the end of its useful lifespan), and Adopt optimal moulding conditions like injection

speed, injection pressure, mould temperature, and proper gas venting.

2. Flow Lines

The problem with flow lines is that they stand out from other areas. Usually, these appear

near the gate points. As with flash, this defect doesn’t alter the functionality of your

injection blow moulding products, but it does take away from their appearance.

Causes: Flow line defects are caused by the varying speed at which the molten plastic flows

as it changes direction through the contours and bends inside the mould tool. They also

occur when the plastic flows through sections with varying wall thickness, or when the

injection speed is too low causing the plastic to solidify at different speeds.

Image No 1.1 flow line formation (source: DieNamic.com)

Remedies: increasing the speed of the moulding cycle of your injection blow moulding

machinery, changing the mould gate locations, adjusting pressure and temperature, and

increasing the nozzle size to improve flow rate.

3. Warping

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Warping (or warpage) is the deformation that occurs when there is uneven shrinkage in the

different parts of the moulded component. The result is a twisted, uneven, or bent shape

where one was not intended.

Image No 1.2 warpage formation (source: DieNamic.com)

Causes: Warping is usually caused by non-uniform cooling of the mould material. Different

cooling rates in different parts of the mould cause the plastic to cool differently and thus

create internal stresses. These stresses, when released, lead to warping.

Remedies: Ensure that the cooling time is sufficiently long and that it is slow enough to

avoid the development of residual stresses being locked into the part, Design the mould with

uniform wall thickness and so that the plastic flows in a single direction, Select plastic

materials that are less likely to shrink and deform. Semi-crystalline materials are generally

more prone to warping.

4. Discoloration

Another defect is discoloration, which can even happen when using the best injection blow

moulding machinery. Obviously, you want your finished products to have a uniform colour,

void of any streaks. Again, this doesn’t alter functionality, only appearance. After each

injection blow moulding process, be sure you thoroughly clean the hopper, mould, nozzle,

and other components. It’s also essential to purge the machine regularly and always use

colouring agents that are properly mixed and have sufficient thermal stability.

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Burn marks: are discolorations, usually rust colours that appear on the surface of the

injection moulded prototypes.

Image No 1.3 Discoloration (burn marks) from ParallelDesign.com

Causes: Burn marks are caused either by the degradation of the plastic material due to

excessive heating or by injection speeds that are too fast. Burn marks can also be caused by

the overheating of trapped air, which etches the surface of the moulded part.

Remedies: Reduce injection speeds, Optimize gas venting and degassing, Reduce mould

and melt temperatures.

5. Air Pockets

Air pockets can also form when using injection blow moulding machinery. When bubbles

become trapped in a finished product, not only do they alter appearance but they can also

weaken the product. Try increasing pressure to force out any bubbles. In addition, have

gates close to the thickest part of the mould, thereby preventing the plastic material from

cooling too quickly. Bubbles are from too high Injection temperature, too much moisture in

material, & non- uniform cooling rate.

6. Weld lines

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They are actually more like a plane than a line that appears in a part where molten plastics

meet each other as they flow from two different parts of the mould.

Image No 1.4 Weld lines from PlasticTroubleshooter.com

Causes: Weld lines are caused by the inadequate bonding of two or more flow fronts when

there is partial solidification of the molten plastic.

Remedies: Raise the temperature of the mould or molten plastic, Increase the injection

speed, Adjust the design for the flow pattern to be a single source flow, and Switch to a less

viscous plastic or one with a lower melting temperature.

7. Vacuum voids

They are pockets of air trapped within or close to the surface of an injection moulded

prototype.

Image No 1.5 Bubbles (voids) from PlasticTroubleshooter.com

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Causes: Vacuum voids are often caused by uneven solidification between the surface and

the inner sections of the prototype. This can be aggravated when the holding pressure is

insufficient to condense the molten plastic in the mould (and thereby force out air that

would otherwise get trapped). Voids can also develop from a part that is cast from a mould

with two halves that are not correctly aligned.

Remedies: Locate the gate at the thickest part of the moulding, Switch to a less viscous

plastic. This will ensure that less gas is trapped as air is able to escape more rapidly,

Increase holding pressure as well as holding time, and ensure that mould parts are perfectly

aligned.

8. Sink marks

They are small craters or depressions that develop in thicker areas of the injection moulded

prototype when shrinkage occurs in the inner portions of the finished product. The effect is

somewhat similar to sinkholes in topography, but caused by shrinkage rather than erosion.

Image No 1.6 Sink marks from PlasticTroubleshooter.com

Causes: Sink marks are often caused when the cooling time or the cooling mechanism is

insufficient for the plastic to fully cool and cure while in the mould. They can also be

caused by inadequate pressure in the cavity, or by an excessive temperature at the gate. All

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else being equal, thick sections of the injection moulded part take longer to cool than thin

ones and so are more likely to be where sink marks are located.

Remedies: Mould temperatures should be lowered, holding pressure increased, and holding

time prolonged to allow for more adequate cooling and curing, Reducing the thickness of

the thickest wall sections will also ensure faster cooling and help reduce the likelihood of

sink marks.

9. Surface delamination

Surface delamination is a condition where thin surface layers appear on the part due to a

contaminant material. These layers appear like coatings and can usually be peeled off (i.e.

“delaminate”).

Image No 1.7 Delamination from PlasticTroubleshooter.com

Causes: Foreign materials that find their way into the molten plastic separate from the

finished product because the contaminant and the plastic cannot bond. The fact that they

cannot bond not only has an effect on the appearance of the prototype, but also on its

strength. The contaminant acts as a localized fault trapped within the plastic. An over-

dependence on mould release agents can also cause delamination.

Remedies: Pre-dry the plastic properly before moulding, Increase the mould temperature,

Smooth out the corners and sharp turns in the mould design to avoid sudden changes in melt

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flow, and focus more on the ejection mechanism in the mould design to reduce or eliminate

the dependence on mould release agents.

10. Short shots

As the term implies, short shots can be described as a situation where a moulding shot falls

short. This means that the molten plastic for some reason does not fully occupy the mould

cavity or cavities, resulting in a portion where there is no plastic. The finished product

becomes deficient because it is incomplete.

Image No 1.8 short shots from PlasticTroubleshooter.com

Causes: Short shots can be caused by a number of things. Incorrect calibration of the shot

or plasticizing capacities can result in the plastic material being inadequate to fill the

cavities. If the plastic is too viscous, it may solidify before fully occupying all the cavities

and result in a short shot. Inadequate degassing or gas venting techniques can also result in

short shots because air is trapped and has no way to escape; plastic material cannot occupy

the space that air or gas is already occupying.

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Remedies: Select a less viscous plastic with higher flow ability, this plastic will fill the

hardest-to-reach cavities, Increase mould or melt temperature so as to increase flow ability,

Account for gas generation by designing the mould so that gas is not trapped within the

mould and is properly vented, Increase the material feed in the moulding machine or switch

to a machine that has a higher material feed in the event that the maximum material feed has

been reached.

1.4 Comprehensive common problems with blow moulding products

1. Uneven vertical wall thickness of blow moulding products

Causes:

 The dead weight droop phenomenon is serious.

 The diameters of the longitudinal two cross sections of the blanks are too different.

Solutions:

 The casting reduces the melt temperature of the billet, improves the extrusion speed,

replaces the resin with lower melt flow speed, and adjusts the control device of the

billet.

 To properly change the product design, using the bottom blow moulding.

2. Non-uniform horizontal wall thickness of blow moulding products

Causes:

 The extruding of extruded blank is skewed.

 The temperature difference between the inner and outer core is large.

 An asymmetrical appearance

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  The blow ratio of the blank is too large.

Solutions:

 The width deviation of die gap is adjusted to make the wall thickness even. Before the

closed mould, straighten out the mould.

 Increase or decrease the heating temperature of the mould sleeve and improve the

deviation of the internal and external temperature of the mould.

 The proclaiming and pre expansion of mould billet are carried out before the plate is

closed, so that the mould billet is offset in the direction of thin wall.

 The billet expansion ratio is reduced by pass.

3. Orange peel pattern or pitted on the surface of the blow moulding products

Causes:

 Exhaust of exhaust mould is poor.

 Water leakage in the upper mould or condensation in the mould cavity

 Due to the poor plasticization of the moulded blank, the melting fracture of the

moulded blank is short of the blowing pressure.

 Air inflation is slow.

 Her blow ratio is too small.

Solutions:

 The blank of jig mould was sandblasted and the air vent was added.

 Repair the mould and adjust the cooling temperature of the mould above “dew point”.

 Lower the screw speed and raise the heating temperature of the extruder.

 To increase the air pressure.

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  Clean air passages and check for air leakage through the air shaft.

 Die change the mould cover, mould core, high billet expansion ratio.

4. Volume reduction of blow moulding products

Causes:

 The thickness of the blank wall increases, resulting in the thickening of the product

wall.

 The increase in shrinkage of contaminated products leads to the reduction in product

size.

 Flat blowing air pressure, products are not blown to the size of the cavity design.

Solutions:

 The main control device of the regulating program reduces the thickness of the blank

wall. The melt temperature of the improved billet decreases the mould expansion

ratio.

 Contact to replace the resin with a lower shrinkage, extend the blowing time, reduce

the mould cooling temperature.

 To properly increase the pressure of compressed air.

5. Unclear outline or text of blow moulding products

Causes:

 Exhaust in the exhaust cavity is poor.

 Air pressure at inlet is low.

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  The melt temperature of medium blank is low, and the material plasticization is not

good.

 Mould cooling temperature is low, mould “condensation” phenomenon.

Solutions:

 Trim the mould, sand blast treatment of the cavity or add an air vent.

 Air pressure increases.

 Increase the heating temperature of the extruder and its head properly, and add

appropriate filler ingredients if necessary.

 Adjust the mould temperature above the dew point temperature

6. Too much flanging and thickness of blow moulding products

Causes:

 The pressure of locking die is insufficient.

 Insert die blade wear, guide column deviation.

 The blank is deflected when blown out

 The discharge chute at the blank edge of the profile clamp is too shallow or the depth

of the blade is too shallow.

 The air charging of the vertiform blank starts too early.

Solutions:

 To increase the mould pressure lock, suitable for reducing the blowing pressure.

 Repair the die blade, correct or replace the die guide.

 Centre position of calibration blank and blowpipe

 Trim the mould to deepen the depth of the discharge chute or knife

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  The filling time of blank is adjusted.

7. Excessively deep vertical stripes

Causes:

 The lip is dirty.

 Insert the mould; the core edge has burr or notch.

 Brown pigment or resin decomposition to produce dark streaks

 Passing through the hole material mixed with impurity deposit in the die.

Solutions:

 Clean the die opening with copper cutter at the front

 Blanking die.

 The temperature should be lowered appropriately and the disperse pigment should be

replaced.

 Replace the filter panel and use the stained leftover material.

8. The moulded embryo is blown apart when forming

Causes:

 The blade edge is too sharp.

 The blank has impurities or bubbles.

 The blow ratio is too large.

 The melt strength of the blank of the blank is low.

 The length of the blank is insufficient.

 The thickness of the blank wall is too thin or uneven.

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  The pressure vessel is expanded and cracked during mould opening (insufficient air

release time).

 The mould locking force is insufficient.

Solutions:

 Suitably increase the width and Angle of the blade.

 Dry raw materials are used in the air, wet raw materials are used after drying, and

clean raw materials are used. Clean up the die.

 Replace the cover and core to reduce the blow ratio

 Replace proper raw materials and lower melt temperature.

 The department checks the control device of extruder or cylinder head, reduces the

change of technological parameters, increases the length of billet, changes the mould

sleeve or core, and thickens the blank wall. Check blank control device; Adjust die

clearance.

 Adjust the air release time or delay the starting time of mould.

 To increase the clamping pressure or reduce the blowing pressure.

9. Difficulty in mould release of blow moulding products

Causes:

 The cooling time is too long and the mould cooling temperature is low.

 Dial mould design is not good, cavity surface has burr.

 The moving speed of front and back plates is not uniform when starting mould.

 Error in mould installation

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Solutions:

 The elastomer shortens the billet inflation time and increases the mould temperature.

Blanking die; Reduce the depth of the groove and the gradient of the convex rib is

1:50 or 1:10 remoulding agent.

 Repair the locking device to make the front and back templates move at the same

speed.

 Reinstall the mould and correct the placement of the two halves.

10. The quality of blow moulding products fluctuates greatly

Causes:

 The thickness of the blank wall changed suddenly.

 The mixing of side and corner return materials are uneven.

 The filling section is blocked, causing fluctuations of extruder output.

 The heating temperature is not uniform.

Solutions:

 Key repair blank control device.

 A good mixing device is used to extend mixing time. Reduce the amount of side –

Angle recycling when necessary.

 Remove the clotting at the vent

 To reduce the temperature at the inlet.

 Replace electrical heating cabinet

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1.5 Methods of analysis extrusion

1.5.1 Test method for analysing extrusion defects using RPA 2000

RPA - The Rubber Process Analyser (RPA 2000) is an advanced (dynamic mechanical

rheological) test instrument, designed to measure the properties of polymers and rubber

compounds before, during and after cure including;

 Processability

 Cure characteristics

 Final cured properties

Extrusion- Compression process in which material is forced to flow through a die orifice to

provide long continuous product whose cross-sectional shape is determined by the shape of

the orifice.

 Extrusion defects that should be analysed by RPA 2000

 Rough surface (Shark Skin) - Defined as a fine surface distortion which runs per

pendicular to the direction of polymer Extrusion.

 High die swell - Die Swell Extruded polymer "remembers" its previous shape when

in the larger cross section of the extruder, tries to return to it after leaving the die

orifice.

 Poor dimension stability

 Heat build up

 Low extrusion rate

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Variable test parameters are; Temperature, oscillation frequency, Strain/angle of

oscillation, & time.

 Main Viscoelastic Parameters for Extrusion

The Elastic (Storage) Modulus: Measure of elasticity of material. The ability of the

material to store

G' = (stress*/strain) cos

The Viscous (loss) Modulus: The ability of the material to dissipate energy. Energy lost as

heat.

G" = (stress*/strain) sin

Tan Delta: Measure of material damping - such as vibration or sound damping.

Shear Thinning: Viscosity decreases with a rise in applied Shear rate.

Tan = G"/G'

Shear Thinning: Viscosity decreases with a rise in applied Shear rate.

1.5.2 Upper bound solution

An upper bound analysis provides an overestimation of the required deformation force. It is

more accurate because it will always result in an overestimation of the load that the press or

the machine will be called upon to deliver. In this case factor of safety will be automatically

built in. In this analysis, the deformation is assumed to take place by rigid body movement of

triangular blocks in which all particles in a given element moves with the some velocity.

A kinematically admissible velocity should satisfy the,

 Continuity equation

XXVIII
  Velocity boundary condition

 Volume constancy condition

The power of deformation calculated from this is higher than the actual one, called upper

bound. When applying upper bound, the first step is to conceive of a velocity field for the

deforming body.

 The field can be easily imagined and related to our visual experience.

 Velocity can be measured directly and is easily displayed in a physical manner.

 In this case factor of safety is automatically in built

 It is comparatively easy to analyse.

There exists an infinite no stress field that satisfy the prescribed condition for a lower bound

solution and an infinite number of velocity that satisfy the upper bound condition. It is

generally assumed that velocity field that the highest lower bound that provides the highest

lower bound is closest in characteristics to the actual velocity. Likewise, generally assume a

stress field that provides highest lower bound the closest to the actual stress distribution.

Theoretical consideration of this process has been neglected as simple analytical techniques

cannot yield valid relationships. Therefore, it has been very difficult to determine the

appropriate working conditions of extrusion and to design the optimum die shape and

dimensions for the required product. For a long time, those matters have been based on

empirical knowledge.

XXIX
 Reference

1. https://maycointernational.com

2. https://knowledge.ulprospector.com

3. https://sadhimachinery.com(difference-between-extrusion-blow-moulding-and-

injection-blow-moulding-process)

4. Belofsky H (1995), “Plastics: Product Design and Process Engineering”

5. Finolex Industries Limited, Corporation Presentation May 2013.

6. Lekhraj Ghai (2014), Importance of PVC in Indian Petrochemical Industry,

Dissertation or Thesis.
XXX
7. Maddock B H (1957), “Factors Affecting Quality in Polyethylene Extrusion”, Modern

Plastics, Vol. 34, No. 8, pp.123-136.

8. Maddock B H (1964), “Measurement and Analysis of Extruder Stability”, SPE

Journal, Vol. 20, pp. 1277-1283.7.

9. Narasimha M and Rejikumar R (2013), “Plastic Pipe Defects Minimization”,

10. International Journal of Innovative Research and Development, Vol. 2, No. 5, pp.

1337-1351.

11. Tadmor Z and Klein I (1970), “Engineering Principles of Plasticising Extrusion”, Van

Nostrand Reinhold Company, New York.

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