Search results for: extrusion process

Authors: Jemal Ebrahim Dessie, Zsolt Lukacs

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The wall of the aerosol can is extruded from the backward extrusion process. Necking is another forming process stage developed on the can shoulder after the backward extrusion process. Due to the thinner thickness of the wall, buckling is the critical challenge for current pure aluminum aerosol can industries. Design and investigation of extrusion with inhomogeneous wall thickness could be the best solution for reducing and optimization of neck retraction numbers. FEM simulation of inhomogeneous wall thickness has been simulated through this investigation. From axisymmetric Deform-2D backward extrusion, an aerosol can with a thickness of 0.4 mm at the top and 0.33 mm at the bottom of the aerosol can have been developed. As the result, it can optimize the number of retractions of the necking process and manufacture defect-free aerosol can shoulder due to the necking process.

Keywords: aerosol can, backward extrusion, Deform-2D, necking

Procedia PDF Downloads 157

Authors: H. Abdolvand, M. Riazat, H. Sohrabi, G. Faraji

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An experimental investigation into the Tube Backward Extrusion (TBE) process on AZ31 magnesium alloy is studied. Microstructures and grain size distribution of the specimens before and after TBE process are investigated by optical microscopy. Tensile and Vickers microhardness tests along extrusion direction were performed at room temperature. It is found that the average grain size is refined remarkably from the initial 33 µm down to 3.5 µm after TBE process. Also, the microhardness increased significantly to 58 HV after the process from an initial value of 36 HV.

Keywords: tube backward extrusion, AZ31, grain size distribution, grain refinement

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Authors: S. M. A. Al Qawabah, A. I. O. Zaid

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Al-4%Cu alloys are now widely used in many engineering applications especially in robotic, aerospace and vibration control area. The main problem arises from the weakness of their mechanical characteristics. Therefore, this study is directed towards enhancing the mechanical properties through severe plastic deformation. In this work, the hot direct extrusion process was chosen to provide the required hot work for this purpose. A direct extrusion die was designed and manufactured to be used in this investigation. The general microstructure, microhardness, surface roughness, and compression tests were performed on specimens from the produced Al-4%Cu alloy both in the as cast and after extrusion conditions. It was found that a pronounced enhancement in the mechanical characteristics of the produced Al-4%Cu after extrusion was achieved. The microhardness increased by 89.3%, the flow stress was decreased by 10% at 0.2 strain and finally the surface roughness was reduced by 81.6%.

Keywords: aluminum, copper, surface roughness, hot extrusion

Procedia PDF Downloads 550

Authors: Abbas Al-Refaie

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This study optimized the performance of plastic extrusion process of drip irrigation pipes using fuzzy goal programming. Two main responses were of main interest; roll thickness and hardness. Four main process factors were studied. The L₁₈ array was then used for experimental design. The individual-moving range control charts were used to assess the stability of the process, while the process capability index was used to assess process performance. Confirmation experiments were conducted at the obtained combination of optimal factor setting by fuzzy goal programming. The results revealed that process capability was improved significantly from -1.129 to 0.8148 for roll thickness and from 0.0965 to 0.714 and hardness. Such improvement results in considerable savings in production and quality costs.

Keywords: fuzzy goal programming, extrusion process, process capability, irrigation plastic pipes

Procedia PDF Downloads 237

Authors: Javeed Akhtar, R. K. Pandey, Z. R. Azaz Ahmad Azad

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For the purpose of making different uses of food material for the development of extruded foods are produced using single and twin extruders. Extrusion cooking is a useful and economical tool for processing of novel food. This high temperature, short time processing technology causes chemical and physical changes that alter the nutritional and physical quality of the product. Extrusion processing of food ingredients characteristically depends on associating process conditions that influence the product qualities. The process parameters are optimized for extrusion of food material in order to obtain the maximum nutritive value by inactivating the anti-nutritional factors. The processing conditions such as moisture content, temperature and time are controlled to avoid over heating or under heating which otherwise would result in a product of lower nutritional quality.

Keywords: extrusion processing, single and twin extruder, operating condition of extruders and extruded novel foods, food and agricultural engineering

Procedia PDF Downloads 358

Authors: Archana Thangavelu, Han-Ik Park, Young-Chul Park, Joon-Hong Park

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In this numerical study, we have proposed a method for evaluation of backward extrusion process of pressure vessel made up of steel. Demand for lighter and stiffer products have been increasing in the last years especially in automobile engineering. Through detailed finite element analysis, effective stress, strain and velocity profile have been obtained with optimal range. The process design of a forward and backward extrusion axe-symmetric part has been studied. Forging is mainly carried out because forged products are highly reliable and possess superior mechanical properties when compared to normal products. Performing computational simulations of 3D hot forging with various dimensions of billet and optimization of weight is carried out using Taguchi Orthogonal Array (OA) Optimization technique. The technique used in this study can be used for newly developed materials to investigate its forgeability for much complicated shapes in closed hot die forging process.

Keywords: backward extrusion, hot forging, optimization, finite element analysis, Taguchi method

Procedia PDF Downloads 287

Authors: D. Zhang, H. Y. Du, G. W. Li, J. Zeng, D. W. Zuo, Y. P. You

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For the difficult issues of process selection, case-based reasoning technology is applied to computer aided process planning system for cold form tapping of internal threads on the basis of similarity in the process. A model is established based on the analysis of process planning. Case representation and similarity computing method are given. Confidence degree is used to evaluate the case. Rule-based reuse strategy is presented. The scheme is illustrated and verified by practical application. The case shows the design results with the proposed method are effective.

Keywords: case-based reasoning, internal thread, cold extrusion, process planning

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Authors: M. Masłowski, M. Zaborski

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Magnetorheological elastomer composites based on micro- and nano-sized magnetite, gamma iron oxide and carbonyl iron powder in ethylene-octene rubber are reported and studied. The method of preparation process influenced the specific properties of MREs (isotropy/anisotropy). The use of extrusion method instead of traditional preparation processes (two-roll mill, mixer) of composites is presented. Micro and nan-sized magnetites as well as gamma iron oxide and carbonyl iron powder were found to be an active fillers improving the mechanical properties of elastomers. They also changed magnetic properties of composites. Application of extrusion process also influenced the mechanical properties of composites and the dispersion of magnetic fillers. Dynamic-mechanical analysis (DMA) indicates the presence of strongly developed secondary structure in vulcanizates. Scanning electron microscopy images (SEM) show that the dispersion improvement had significant effect on the composites properties. Studies investigated by vibration sample magnetometer (VSM) proved that all composites exhibit good magnetic properties.

Keywords: extrusion, magnetic fillers, magnetorheological elastomers, mechanical properties

Procedia PDF Downloads 299

Authors: Arash Sharafat Vaziri, Leila Aghaghazvini, Soodeh Jahangiri, Mohammad Tahami, Roham Borazjani, Mohammad Naghi Tahmasebi, Hamid Rabie, Hesan Jelodari Mamaghani, Fardis Vosoughi, Maryam Salimi

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Aims: It is essential to know the normal extrusion measures in order to detect pathological ones. In this study, we aimed to define some normal reference values for meniscal extrusion in the normal knees during different ranges of motion. Methods: The amount of anterior and posterior portion of meniscal extrusion among twenty-one asymptomatic volunteers (42 knees) were tracked at 0, 45, and 90 degrees of knee flexion using an ultrasound machine. The repeated measures analysis of variance (ANOVA) was used to show the interaction between the amounts of meniscal extrusion and the different degrees of knee flexion. Result: The anterior portion of the lateral menisci at full knee extension (0.59±1.40) and the posterior portion of the medial menisci during 90° flexion (3.06±2.36) showed the smallest and the highest mean amount of extrusion, respectively. The normal average amounts of anterior extrusion were 1.12± 1.17 mm and 0.99± 1.34 mm for medial and lateral menisci, respectively. The posterior meniscal normal extrusions were significantly increasing in both medial and lateral menisci during the survey (F= 20.250 and 11.298; both P-values< 0.001) as they were measured at 2.37± 2.16 mm and 1.53± 2.18 mm in order. Conclusion: The medial meniscus can extrude 1.74± 1.84 mm normally, while this amount was 1.26± 1.82 mm for the lateral meniscus. These measures commonly increased with the rising of knee flexion motion. Likewise, the posterior portion showed more extrusion than the anterior portion on both sides. These measures commonly increased with higher knee flexion.

Keywords: meniscal extrusion, ultrasonography, knee

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Authors: C. H. Jeon, Y. H. Kim, G. A. Lee

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Reducing resource consumption and carbon dioxide emission are recognized as urgent issues. One way of resolving these issues is to reduce product weight. Magnesium alloys are considered promising candidates because of their lightness. Various studies have been conducted on using magnesium alloy instead of conventional iron or aluminum in mechanical parts, due to the light weight and superior specific strength of magnesium alloy. However, even stronger magnesium alloys are needed for mechanical parts. One common way to enhance the strength of magnesium alloy is by extruding the ingot. In order to enhance the mechanical properties, magnesium alloy ingot were extruded at various extrusion ratios. Relationship between extrusion ratio and mechanical properties was examined on extruded material of magnesium alloy. And Textures and microstructures of the extruded materials were investigated.

Keywords: extrusion, extrusion ratio, magnesium, mechanical property, lightweight material

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Authors: Adnan I. O. Zaid, Safwan M. A. Alqawabah

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Review of the available literature on grain refinement of aluminum and its alloys reveals that little work is published on the effect of refiners on mechanical characteristics and wear resistance. In this paper, the effect of addition of Zr to Al grain refined by Ti+B on its metallurgical, mechanical characteristics and wear resistance both in the as cast and after extrusion condition are presented and discussed. It was found that Addition of Zr to Al resulted in deterioration of its mechanical strength and hardness, whereas it resulted in improvement of both of them when added to Al grain refined by Ti+B. Furthermore it was found that the direct extrusion process resulted in further increase of the mechanical strength and hardness of Al and its micro-alloys. Also it resulted in increase of their work hardening index, n, i.e. improved their formability, hence it reduces the number of stages required for forming at large strains in excess of the plastic instability before Zr addition.

Keywords: aluminum, grain refinement, titanium + boron, zirconium, mechanical characteristics, wear resistance, direct extrusion

Procedia PDF Downloads 417

Authors: V. E. Bazhenov, A. V. Li, A. A. Komissarov, A. V. Koltygin, S. A. Tavolzhanskii, O. O. Voropaeva, A. M. Mukhametshina, A. A. Tokar, V. A. Bautin

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Magnesium-based alloys are considered as effective materials in the development of biodegradable implants. The magnesium alloys containing Mg, Zn, Ca as an alloying element are the subject of the particular interest. These elements are the nutrients for the human body, which provide their high biocompatibility. In this work, we investigated the effect of severe plastic deformation (SPD) on the mechanical and corrosion properties of Mg-Zn-Ca and Mg-Zn-Ca-Mn alloys containing from 2 to 4 wt.% Zn; 0.7 wt.% Ca and up to 1 wt.% Mn. Hot extrusion was used as a method of intensive plastic deformation. The temperature of hot extrusion was set to 220 °C and 300 °C. Metallographic analysis after hot extrusion shows that the grain size in the studied alloys depends on the deformation temperature. The grain size for all of investigated alloys is in the range from 3 to 7 microns, and 3 μm corresponds to the extrusion temperature of 220 °C. Analysis of mechanical properties after extrusion shows that extrusion at a temperature of 220 °C and alloying with Mn increase the strength characteristics and decrease the ductility of studied alloys. A slight anisotropy of properties in the longitudinal and transverse directions was also observed. Measurements of corrosion properties revealed that the addition of Mn to Mg-Zn-Ca alloys reduces the corrosion rate. On the other hand, increasing the Zn content in alloys increases the corrosion rate. The extrusion temperature practically does not affect the corrosion rate. Acknowledgement: The authors gratefully acknowledge the financial support of the Ministry of Science and Higher Education of the Russian Federation in the framework of Increase Competitiveness Program of NUST «MISiS» (No K2-2019-008), implemented by a governmental decree dated 16th of March 2013, N 211.

Keywords: biocompatibility, hot extrusion, magnesium alloys, severe plastic deformation, properties

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Authors: A. Eghbali, M. Goodarzi, M. Hagh Panahi

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In this article process of direct extrusion of axisymmetric bimetallic tube with conic die profile and constant Mandrel by upper bound method has been analyzed and finite element method is simulated. Deformation area is divided into six smaller deformation areas and are calculated by presenting two generalized velocity field and applicable input and output sections separately (velocity profile with logarithmic curve for input section and spherical velocity profile for materials output ) for each die profile in spherical coordinate system strain rate values in every deformation area. After internal power, shearing power and material friction power is obtained, extrusion force is calculated. The results of upper bound analysis method with given results from other researcher's experiments and simulation by finite parts method (Abaqus software) are compared for conic die.

Keywords: extrusion, upper bound, axisy metric, deformation velocity field

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Authors: Ha-Guk Jeong, Jong-Beom Lee

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Cladding process is very typical technology for manufacturing composite materials by the hydrostatic extrusion. Because there is no friction between the metal and the container, it can be easily obtained in uniform flow during the deformation. The general manufacturing process for a metal-matrix composite in the solid state, mixing metal powders and ceramic powders with a suited volume ratio, prior to be compressed or extruded at the cold or hot condition in a can. Since through a plurality of unit processing steps of dispersing the materials having a large difference in their characteristics and physical mixing, the process is complicated and leads to non-uniform dispersion of ceramics. It is difficult and hard to reach a uniform ideal property in the coherence problems at the interface between the metal and the ceramic reinforcements. Metal hybrid composites, which presented in this report, are manufactured through the traditional plastic deformation processes like hydrostatic extrusion, caliber-rolling, and drawing. By the previous process, the realization of uniform macro and microstructure is surely possible. In this study, as a constituent material, aluminum, copper, and titanium have been used, according to the component ratio, excellent characteristics of each material were possible to produce a metal hybrid composite that appears to maximize. MgB₂ superconductor wire also fabricated via the same process. It will be introduced to their unique artistic and thermal characteristics.

Keywords: cladding process, metal-hybrid composites, hydrostatic extrusion, electronic/thermal characteristics

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Authors: Eva Savy, Anthony Ruiz

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In extrusion blow molding, there is great variability in product quality due to the sensitivity of the machine settings. These variations lead to unnecessary rejects and loss of time. Yet production control is a major challenge for companies in this sector to remain competitive within their market. Current quality control methods only apply to finished products (vision control, leak test...). It has been shown that material melt temperature, blowing pressure, and ambient temperature have a significant impact on the variability of product quality. Since blowing is a key step in the process, we have studied this parameter in this paper. The objective is to determine if airflow analysis allows the identification of quality problems before the full completion of the manufacturing process. We conducted tests to determine if it was possible to identify a leakage defect and an obstructed defect, two common defects on products. The results showed that it was possible to identify a leakage defect by airflow analysis.

Keywords: extrusion blow molding, signal, sensor, defects, detection

Procedia PDF Downloads 110

Authors: Adnan I. O. Zaid, Raghad S. Hemeimat

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Magnesium - aluminum alloys are versatile materials which are used in manufacturing a number of engineering and industrial parts in the automobile and aircraft industries due to their strength – to –weight -ratio. Against these preferable characteristics, magnesium is difficult to deform at room temperature therefore it is alloyed with other elements mainly Aluminum and Zinc to add some required properties particularly for their high strength - to -weight ratio. Mg and its alloys oxidize rapidly therefore care should be taken during melting or machining them; but they are not fire hazardous. Grain refinement is an important technology to improve the mechanical properties and the micro structure uniformity of the alloys. Grain refinement has been introduced in early fifties; when Cibula showed that the presence of Ti, and Ti+ B, produced a great refining effect in Al. since then it became an industrial practice to grain refine Al. Most of the published work on grain refinement was directed toward grain refining Al and Zinc alloys; however, the effect of the addition of rare earth material on the grain size or the mechanical behavior of Mg alloys has not been previously investigated. This forms the main objective of the research work; where, the effect of Ti addition on the grain size, mechanical behavior, ductility, and the extrusion force & energy consumed in forward extrusion of Mg-AZ31 alloy is investigated and discussed in two conditions, first in the as cast condition and the second after extrusion. It was found that addition of Ti to Mg- AZ31 alloy has resulted in reduction of its grain size by 14%; the reduction in grain size after extrusion was much higher. However the increase in Vicker’s hardness was 3% after the addition of Ti in the as cast condition, and higher values for Vicker’s hardness were achieved after extrusion. Furthermore, an increase in the strength coefficient by 36% was achieved with the addition of Ti to Mg-AZ31 alloy in the as cast condition. Similarly, the work hardening index was also increased indicating an enhancement of the ductility and formability. As for the extrusion process, it was found that the force and energy required for the extrusion were both reduced by 57% and 59% with the addition of Ti.

Keywords: cast condition, direct extrusion, ductility, MgAZ31 alloy, super - plasticity

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Authors: Pedro Henrique Alves Martins, Paulo Guilherme Ferreira De Siqueira, Franco De Castro Bubani, Maria Teresa Paulino Aguilar, Paulo Roberto Cetlin

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Cu-base shape-memory alloys (CuZnAl, CuAlNi, CuAlBe, etc.) are promising engineering materials for several unconventional devices, such as sensors, actuators, and mechanical vibration dampers. Brittleness is one of the factors that limit the commercial use of these alloys, as it makes thermomechanical processing difficult. In this work, a method for the hot extrusion of a 75.50% Cu, 16,74% Zn, 7,76% Al (weight %) alloy is presented. The effects of the thermomechanical processing in the microstructure and the pseudoelastic behavior of the alloy are assessed by optical metallography, compression and hardness tests. Results show that hot extrusion is a suitable method to obtain severe cross-section reductions in the CuZnAl shape-memory alloy studied. The alloy maintained its pseudoelastic effect after the extrusion and the modifications in the mechanical behavior caused by precipitation during hot extrusion can be minimized by a suitable precipitate dissolution heat treatment.

Keywords: hot extrusion, pseudoelastic, shape-memory alloy, thermomechanical processing

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Authors: L. Strauta, S. Muižniece-Brasava

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Even though legumes possess high nutritional value and have a rather high protein content for plant origin products, they are underutilized mostly due to their lengthy cooking time. To increase the presence of legume-based products in human diet, new extruded products were made of cow peas (Vigna unguiculata (L.) Walp.). But as it is known, adding different moisture content to flour before extrusion can change the physical properties of the extruded product. Experiments were carried out to estimate the optimal moisture content for cow pea extrusion. After extrusion, the pH level had dropped from 6.7 to 6.5 and the lowest hardness rate was observed in the samples with additional 9 g 100g^-1 of moisture - 28±4N, but the volume mass of the samples with additional 9 g100g^-1 of water was 263±3 g L^-1; all samples were approximately 7±1mm long.

Keywords: cow pea, extrusion–cooking, moisture, size

Procedia PDF Downloads 188

Authors: Krishna Nand, Mohammad Taufik

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Fused Filament Fabrication (FFF) is one of the most popular additive manufacturing (AM) technology. In FFF technology, a wire form material (filament) is fed inside a heated chamber, where it gets converted into semi-solid form and extruded out of a nozzle to be deposited on the build platform to fabricate the part. FFF technology is expanding and covering the market at a very rapid rate, so the need of raw materials for 3D printing is also increasing. The cost of 3D printing is directly affected by filament cost. To make 3D printing more economic, a compact and portable filament/wire extrusion system is needed. Wire extrusion systems to extrude ordinary wire/filament made of a single material are available in the market. However, extrusion system to make a composite wire/filament are not available. Hence, in this study, initial efforts have been made to develop a table-top composite wire extruder. The developed system is consisted of mechanical parts, electronics parts, and a control system. A multiple channel hopper, extrusion screw, melting chamber and nozzle, cooling zone, and spool winder are some mechanical parts. While motors, heater, temperature sensor, cooling fans are some electronics parts, which are used to develop this system. A control board has been used to control the various process parameters like – temperature and speed of motors. For the production of composite wire/filament, two different materials could be fed through two channels of hopper, which will be mixed and carried to the heated zone by extrusion screw. The extrusion screw is rotated by a motor, and the speed of this motor will be controlled by the controller as per the requirement of material extrusion rate. In the heated zone, the material will melt with the help of a heating element and extruded out of the nozzle in the form of wire. The developed system occupies less floor space due to the vertical orientation of its heating chamber. It is capable to extrude ordinary filament as well as composite filament, which are compatible with 3D printers available in the market. Further, the developed system could be employed in the research and development of materials, processing, and characterization for 3D printer. The developed system presented in this study could be a better choice for hobbyists and researchers dealing with the fused filament fabrication process to reduce the 3D printing cost significantly by recycling the waste material into 3D printer feed material. Further, it could also be explored as a better alternative for filament production at the commercial level.

Keywords: additive manufacturing, 3D Printing, filament extrusion, pellet extrusion

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Authors: Shilpa Kumari, Ramakumar Jayachandran

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Machining of aluminium extrusion profiles in the automotive industry has gained much interest in the last decade, particularly due to the higher utilization of aluminum profiles and the weight reduction benefits it brings. Milling is the most common material removal process, where the rotary milling cutter is moved against a workpiece. The physical contact of the milling cutter to the workpiece increases the friction between them, thereby affecting the longevity of the milling tool and also the surface finish of the workpiece. To minimise this issue, the milling process uses cutting fluids or emulsions; however, the use of emulsion in the process has a negative impact on the environment ( such as consumption of water, oils and the used emulsion needs to be treated before disposal) and also on the personal ( may cause respiratory problems, exposure to microbial toxins generated by bacteria in the emulsions on prolonged use) working close to the process. Furthermore, the workpiece also needs to be cleaned after the milling process, which is not adding value to the process, and the cleaning also disperses mist of emulsion in the working environment. Hydro Extrusion is committed to improving the performance of sustainability from its operations, and with the negative impact of using emulsion in the milling process, a new innovative process- Dry Milling was developed to minimise the impact the cutting fluid brings. In this paper, the authors present one application of dry milling in the machining of tensile specimens in the laboratory. Dry milling is an innovative milling process without the use of any cooling/lubrication and has several advantages. Several million tensile tests are carried out in extrusion laboratories worldwide with the wet milling process. The machining of tensile specimens has a significant impact on the reliability of test results. The paper presents the results for different 6xxx alloys with different wall thicknesses of the specimens, which were machined by both dry and wet milling processes. For both different 6xxx alloys and different wall thicknesses, mechanical properties were similar for samples milled using dry and wet milling. Several tensile specimens were prepared using both dry and wet milling to compare the results, and the outcome showed the dry milling process does not affect the reliability of tensile test results.

Keywords: dry milling, tensile testing, wet milling, 6xxx alloy

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Authors: Jiahe Ru, Yan Pang, Zhaomiao Liu

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Necking processes of the Janus droplet generation in the cross-junction microchannels are experimentally and theoretically investigated. The two dispersed phases that are simultaneously shear by continuous phases are liquid paraffin wax and 100cs silicone oil, in which 80% glycerin aqueous solution is used as continuous phases. According to the variation of minimum neck width and thinning rate, the necking process is divided into two stages, including the two-dimensional extrusion and the three-dimensional extrusion. In the two-dimensional extrusion stage, the evolutions of the tip extension length for the two discrete phases begin with the same trend, and then the length of liquid paraffin is larger than silicone oil. The upper and lower neck interface profiles in Janus necking process are asymmetrical when the tip extension velocity of paraffin oil is greater than that of silicone oil. In the three-dimensional extrusion stage, the neck of the liquid paraffin lags behind that of the silicone oil because of the higher surface tension, and finally, the necking fracture position gradually synchronizes. When the Janus droplets pinch off, the interfacial tension becomes positive to drive the neck thinning. The interface coupling of the three phases can cause asymmetric necking of the neck interface, which affects the necking time and, ultimately, the droplet volume. This paper mainly investigates the thinning dynamics of the liquid-liquid interface in confined microchannels. The revealed results could help to enhance the physical understanding of the droplet generation phenomenon.

Keywords: neck interface, interface coupling, janus droplets, multiphase flow

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Authors: Jong-Yeon Kim, Kwang-Bok Shin, Tae-Hwan Ko

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The purpose of this paper is to suggest a weight-reduction design method for the aluminum extrusion carbody structure of a double deck high-speed train using size optimization method. The size optimization method was used to optimize thicknesses of skin and rib of the aluminum extrusion for the carbody structure. Thicknesses of 1st underframe, 2nd underframe, solebar and roof frame were selected by design variables in order to conduct size optimization. The results of the size optimization analysis showed that the weight of the aluminum extrusion could be reduced by 0.61 tons (5.60%) compared to the weight of the original carbody structure.

Keywords: double deck high-speed train, size optimization, weigh-reduction, aluminum extrusion

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Authors: C. S. Saini

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The composite flour blend consisting of corn, pearl millet, black gram and wheat bran in the ratio of 80:5:10:5 was taken to prepare the extruded product and their effect on physical properties of extrudate was studied. The extrusion process was conducted in laboratory by using twin screw extruder. The physical characteristics evaluated include lateral expansion, bulk density, water absorption index, water solubility index, rehydration ratio and moisture retention. The Central Composite Rotatable Design (CCRD) was used to decide the level of processing variables i.e. feed moisture content (%), screw speed (rpm), and barrel temperature (oC) for the experiment. The data obtained after extrusion process were analyzed by using response surface methodology. A second order polynomial model for the dependent variables was established to fit the experimental data. The numerical optimization studies resulted in 127°C of barrel temperature, 246 rpm of screw speed, and 14.5% of feed moisture as optimum variables to produce acceptable extruded product. The responses predicted by the software for the optimum process condition resulted in lateral expansion 126 %, bulk density 0.28 g/cm3, water absorption index 4.10 g/g, water solubility index 39.90 %, rehydration ratio 544 % and moisture retention 11.90 % with 75 % desirability.

Keywords: black gram, corn flour, extrusion, physical characteristics

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Authors: Daniel Nelson, Valeria La Saponara

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Material extrusion is an additive manufacturing modality that continues to show great promise in the ability to create low-cost, highly intricate, and exceedingly useful structural elements. As more capable and versatile filament materials are devised, and the resolution of manufacturing systems continues to increase, the need to understand and predict manufacturing-induced warping will gain ever greater importance. The following study presents an in situ remote sensing and data analysis construct that allows for the in situ mapping and quantification of surface displacements induced by residual stresses on a specified test structure. This proof-of-concept experimental process shows that it is possible to provide designers and manufacturers with insight into the manufacturing parameters that lead to the manifestation of these deformations and a greater understanding of the behavior of these warping events over the course of the manufacturing process.

Keywords: additive manufacturing, deformation, digital image correlation, fused filament fabrication, residual stress, warping

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Authors: Hasika Mith, Hassany Ly, Hengsim Phoung, Rathana Sovann, Pichmony Ek, Sokuntheary Theng

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Rice is one of the most important crops used in the production of ready-to-cook (RTC) products such as rice vermicelli, noodles, rice paper, Banh Kanh, wine, snacks, and desserts. Meanwhile, extrusion is the most creative food processing method used for developing products with improved nutritional, functional, and sensory properties. This method authorizes process control such as mixing, cooking, and product shaping. Therefore, the objectives of this study were to produce rice vermicelli using a twin screw extruder, and the cooking properties of extruded rice vermicelli were investigated. Response Surface Methodology (RSM) with Box-Behnken design was applied to optimize extrusion conditions in order to achieve the most desirable product characteristics. The feed moisture rate (30–35%), the barrel temperature (90–110°C), and the screw speed (200–400 rpm) all play a big role and have a significant impact on the water absorption index (WAI), cooking yield (CY), and cooking loss (CL) of extrudate rice vermicelli. Results showed that the WAI of the final extruded rice vermicelli ranged between 216.97% and 571.90%. The CY ranged from 147.94 to 203.19%, while the CL ranged from 8.55 to 25.54%. The findings indicated that at a low screw speed or low temperature, there are likely to be more unbroken polymer chains and more hydrophilic groups, which can bind more water and make WAI values higher. The extruded rice vermicelli's cooking yield value had altered considerably after processing under various conditions, proving that the screw speed had little effect on each extruded rice vermicelli's CY. The increase in barrel temperature tended to increase cooking yield and reduce cooking loss. In conclusion, the extrusion processing by a twin-screw extruder had a significant effect on the cooking quality of the rice vermicelli extrudate.

Keywords: cooking loss, cooking quality, cooking yield, extruded rice vermicelli, twin-screw extruder, water absorption index

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Authors: Mohamed S. El-Asfoury, Ahmed Abdel-Moneim, Mohamed N. A. Nasr

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The current study uses finite element modeling to investigate and analyze a modified form of the from the conventional equal channel multi-angular pressing (ECMAP), using non-equal channels, on the workpiece material plastic deformation. The modified process non-equal channel multi-angular extrusion (NECMAE) is modeled using two-dimensional plane strain finite element model built using the commercial software ABAQUS. The workpiece material used is pure aluminum. The model was first validated by comparing its results to analytical solutions for single-pass equal channel angular extrusion (ECAP), as well as previously published data. After that, the model was used to examine the effects of different % of reductions of the area (for the second stage) on material plastic deformation, corner gap, and required the load. Three levels of reduction in the area were modeled; 10%, 30%, and 50%, and compared to single-pass and double-pass ECAP. Cases with a higher reduction in the area were found to have smaller corner gaps, higher and much uniform plastic deformation, as well as higher required loads. The current results are mainly attributed to the back pressure effects exerted by the second stage, as well as strain hardening effects experienced during the first stage.

Keywords: non-equal channel angular extrusion, multi-pass, sever plastic deformation, back pressure, Finite Element Modelling (FEM)

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Authors: H. Kharmoudi, S. Elkoun, M. Robert, C. Diez

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In the literature, the elaboration of polymer blends based on recycled HDPE and LDPE is challenging because of the non-miscibility. Ensuring the compatibility of blends is one of the challenges; this study will discuss the different methods to be adopted to assess the compatibility of polymer blends. The first one aims to act on the extrusion process while varying the speed, flow rate, and residence time. The second method has as its purpose the use of grafted anhydride maleic elastomer chains as a compatibilizer. The results of the formulations will be characterized by means of differential scanning calorimetric (DSC) as well as mechanical tensile and bending tests to assess whether pipes made from recycled polyethylene meet the standards.

Keywords: recycled HDPE, LDPE, compatibilizer, mechanical tests

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Authors: Efrain Rodriguez, Sergio Pertuz, Cristhian Riano

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Tool-path generation is an essential step in the FFF (Fused Filament Fabrication)-based Additive Manufacturing (AM) process planning. In the manufacture of a mechanical part by using additive processes, high resource consumption and prolonged production times are inherent drawbacks of these processes mainly due to non-optimized tool-path generation. In this work, we propose a heuristic-search intelligent algorithm-based approach for optimized tool-path generation for FFF-based AM. The main benefit of this approach is a significant reduction of travels without material deposition when the AM machine performs moves without any extrusion. The optimization method used reduces the number of travels without extrusion in comparison with commercial software as Slic3r or Cura Engine, which means a reduction of production time.

Keywords: additive manufacturing, tool-path optimization, fused filament fabrication, process planning

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Authors: Alberto A. Escobar Puentes, G. Adriana García, Luis F. Cuevas G., Alejandro P. Zepeda, Fernando B. Martínez, Susana A. Rincón

Abstract:

Snack foods are usually classified as ‘junk food’ because have little nutritional value. However, due to the increase on the demand and third generation (3G) snacks market, low price and easy to prepare, can be considered as carriers of compounds with certain nutritional value. Resistant starch (RS) is classified as a prebiotic fiber it helps to control metabolic problems and has anti-cancer colon properties. The active compound can be developed by chemical cross-linking of starch with phosphate salts to obtain a type 4 resistant starch (RS4). The chemical reaction can be achieved by extrusion, a process widely used to produce snack foods, since it's versatile and a low-cost procedure. Starch is the major ingredient for snacks 3G manufacture, and the seeds of sorghum contain high levels of starch (70%), the most drought-tolerant gluten-free cereal. Due to this, the aim of this research was to develop a snack (3G), with RS4 in optimal conditions extrusion (previously determined) from sorghum starch, and carry on a sensory, chemically and structural characterization. A sample (200 g) of sorghum starch was conditioned with 4% sodium trimetaphosphate/ sodium tripolyphosphate (99:1) and set to 28.5% of moisture content. Then, the sample was processed in a single screw extruder equipped with rectangular die. The inlet, transport and output temperatures were 60°C, 134°C and 70°C, respectively. The resulting pellets were expanded in a microwave oven. The expansion index (EI), penetration force (PF) and sensory analysis were evaluated in the expanded pellets. The pellets were milled to obtain flour and RS content, degree of substitution (DS), and percentage of phosphorus (% P) were measured. Spectroscopy [Fourier Transform Infrared (FTIR)], X-ray diffraction, differential scanning calorimetry (DSC) and scanning electron microscopy (SEM) analysis were performed in order to determine structural changes after the process. The results in 3G were as follows: RS, 17.14 ± 0.29%; EI, 5.66 ± 0.35 and PF, 5.73 ± 0.15 (N). Groups of phosphate were identified in the starch molecule by FTIR: DS, 0.024 ± 0.003 and %P, 0.35±0.15 [values permitted as food additives (<4 %P)]. In this work an increase of the gelatinization temperature after the crosslinking of starch was detected; the loss of granular and vapor bubbles after expansion were observed by SEM; By using X-ray diffraction, loss of crystallinity was observed after extrusion process. Finally, a snack (3G) was obtained with RS4 developed by extrusion technology. The sorghum starch was efficient for snack 3G production.

Keywords: extrusion, resistant starch, snack (3G), Sorghum

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Authors: Satya P. Dubey, Hrushikesh A Abhyankar, Veronica Marchante, James L. Brighton, Björn Bergmann

Abstract:

Aims: To develop a mathematical model that simulates the ROP of PLA taking into account the effect of alternative energy to be implemented in a continuous reactive extrusion production process of PLA. Introduction: The production of large amount of waste is one of the major challenges at the present time, and polymers represent 70% of global waste. PLA has emerged as a promising polymer as it is compostable, biodegradable thermoplastic polymer made from renewable sources. However, the main limitation for the application of PLA is the traces of toxic metal catalyst in the final product. Thus, a safe and efficient production process needs to be developed to avoid the potential hazards and toxicity. It has been found that alternative energy sources (LASER, ultrasounds, microwaves) could be a prominent option to facilitate the ROP of PLA via continuous reactive extrusion. This process may result in complete extraction of the metal catalysts and facilitate less active organic catalysts. Methodology: Initial investigation were performed using the data available in literature for the reaction mechanism of ROP of PLA based on conventional metal catalyst stannous octoate. A mathematical model has been developed by considering significant parameters such as different initial concentration ratio of catalyst, co-catalyst and impurity. Effects of temperature variation and alternative energies have been implemented in the model. Results: The validation of the mathematical model has been made by using data from literature as well as actual experiments. Validation of the model including alternative energies is in progress based on experimental data for partners of the InnoREX project consortium. Conclusion: The model developed reproduces accurately the polymerisation reaction when applying alternative energy. Alternative energies have a great positive effect to increase the conversion and molecular weight of the PLA. This model could be very useful tool to complement Ludovic® software to predict the large scale production process when using reactive extrusion.

Keywords: polymer, poly-lactic acid (PLA), ring opening polymerization (ROP), metal-catalyst, bio-degradable, renewable source, alternative energy (AE)

Procedia PDF Downloads 339