Acorn Meadow Designs
445 Grange Road North Smithfield, RI 02896
Toll Free: 866-765-3833
Tel: 401-765-3833 (Fax 401-633-6142)
PROJECT SUMMARY
Combining block for plastic co-extrusion.
GOAL:
A world class international manufacturer of specialty plastic film had successful production tooling that combined flows from two extruders for making 3 layer film. They wanted to duplicate the tooling and add two extruders to make 5 layer film.
STARTING POINT:
The manufacturer had old hand drawn prints
used to make the original tooling overseas. They had a production line with
a large main extruder and one smaller co-extruder for the outer layers.
They wanted to prove the concept by building a new combining block and
connecting it to the existing extruder prior to investing in 2 complete new
additional extruders.
SCOPE OF WORK:
Acorn Meadow Designs first used CMM data obtained by the manufacturer of two existing tools and compared that to theoretical forms from the old tooling prints. Aided by AMD’s analysis and visual representation of results, the manufacturer’s polymer engineers determined how the shape should be modified to obtain their desired layer uniformity.
AMD reverse engineered the precision multi part tooling, adding new features such as an easily replaceable flow insert which contained the important flow distribution contour. AMD engineered a new external manifold to split the flow of the existing small extruder to supply the new combining block as well as the old block to simulate the existence of the proposed new extruders. All design work was done in a solid modeling environment. The tooling was built by AMD sub-contractors and extensively measured for resulting flow contour confirmation.
The manufacturer installed and tested the tooling and found improved distribution over the old tooling. Distribution still needed to be more uniform so a second insert with modified flow contours was designed and built. This insert resulted in significantly more uniform flow distribution and was so satisfactory that it replaced the tooling that had been in production for years.
Procurement and installation of the additional new extruders is now on going.
FEATURES:
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Tooling measurement, analysis, and visual representation approach helped extrusion engineers define improved flow contours.
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New tooling improved flow distribution over existing design.
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New tooling allows more cost effective modification of combining performance through use of replaceable insert.
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New tooling successfully interfaced to precise connections to existing combining block, main melt pipes, co-extruder melt pipes and extrusion die.
