Ultrasonically enhanced flow rate of polymer melt extrusion Online publication date: Thu, 29-Sep-2022
by Matthew D. Moles; Anish Roy; Vadim V. Silberschmidt
International Journal of Materials and Structural Integrity (IJMSI), Vol. 14, No. 2/3/4, 2021
Abstract: Currently, the innovation of thin-section polymeric parts formed by injection moulding is restricted by the economics and practicality of applying high levels of temperature and pressure during the manufacturing process. It is long recognised that subjecting non-Newtonian fluids to vibration can significantly enhance the flow rate and, hence, may be used to reduce pressure and thermal requirements in thin-section moulding. A new moulding process was developed using ultrasonic transducers to induce vibrations in the polymeric melt thereby enhancing the flow rate without degradation of the polymer. Generating ultrasound using piezoceramics mounted in close proximity to the extrusion die required a custom-designed heat-protected transducer stack. The device, with its extrusion die exposing the polymer melt to low-intensity vibrations, improved the flow rate of polypropylene by 33% in batch exposure mode.
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