Transcript presentation on injection,extrustion,blow,bimetallic,rebulding

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Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik
Pvt. Ltd. has become world renowned as screw and barrel specialists.
We manufacture feed screws of the highest quality, and provide service and a product
that is second to none.
We service the plastics and rubber industries to processors and OEMs worldwide,
countries such as USA , UK ,EUROPE, RUSSIA,MIDDLE EAST,AFRICA,ASIAN
Countries etc…..
Our Technical and Engineering Department offers more than 15 years of experience in
the field of plastic machinery and screw design.
We have developed our own line of screw designs which can be tailored to suit your
application.
We stand behind the parts we produce and provide long term support for our products.
Ever since it & we believe in the quality first, honesty to customers, prompt services to
customer’s satisfaction.
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Our comprehensive production facilities enable us to perform the entire manufacturing
process in-house. As for new screw or old rebuild screw , we utilize traditional methods
to achieve the highest international standards.
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Feed screw cutting machines over 6m (20 ft.) long x 20 cm (8 in.) diameter
Milling and turning
Welding of hard facings
Heat treatments (Ion & Gas nitriding, Vaccum hardening)
Chrome plating max. length 6 m (20 ft.)
Deep hole boring/trepanning
Honing
200 ton press
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To assist in ameliorating the designs off different Screws & Barrels for running
different plastics polymers.
To assist in increasing your extruder’s out put as well as prolonging its service
life.
To assist in increasing your extruders according to your specific melt quality.
Better processing of film and reduce scrap and also cost saving of resins.
Speedy returns on your initial high investments by our products.
Kaivanya extrusion use strong R&D skill work closely with our customers to
ensure quality products that produce high end output at a very economical
price.
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Plasma Nitriding furnace
Microscopic Structure
Hardness Teter
Quality Control
Thread Milling
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KAIVANYA EXTRUSTION TECHNIK
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Extrusion moulding is a manufacturing process used to make
pipes,filim,hoses,drinking straws, curtain tracks, rod and fiber,yarn,cable &
wire,sheet,rope,sutli,&other product.
The machine used to extrude materials is very similar to injection molding machine.
A motor turns a screw which feeds granules of plastic through a heater. The granules
melt into a liquid which is forced through a die , forming a long 'tube like' shape. The
shape of the die determines the shape of the tube. The extrusion is then cooled and
forms a solid shape. The tube may be printed upon, and cut at equal intervals.
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Screws are made from nitro alloy steel like 34CrAlNi7, 41CrAlMo7 etc.
toughening, tempering, stress relieving, gas nitriding & additional bimetallic
coatings can be incorporated on flights depending on the process application.
We also do special surface treatment like hard nickel plating, chrome plating &
titanium coating depending on the material to be proceed.
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Our ability to design and manufacture some of the industry’s most advanced
and efficient feed screws is one reason we have been an extrusion leader for
more than 15 years. With our R&D facilities and team of experienced polymer
process engineers, we offer customers world class screw design and technical
capabilities.
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KAIVANYA EXTRUSION Engineering is the largest and by far the oldest
manufacturer of extrusion screws in India.
Our designs cover all facets of the extrusion industry from thermoplastics to natural and
synthetic rubber.
We have a 13 year plus record in this industry from which we have built up significant
data, soundly based on experience and results.
Screw construction is hard faced, nitrided or hardened & nitrided, for highly abrasive
materials we can supply screws with Tungsten carbide coatings on the flight flanks and
core diameters, or in the case of highly corrosive polymers such as Fluoro polymer a
Duranickle based screw is offered.
Designs are available for single flight metering screws, single barrier screws, double
barrier screws, variable pitch flights, multi start flights and slotted flights.
Two stage screws for vented extruders are also offered.
Mixing sections, the more common of which, include Maddock (spiral or straight),
Hoechst, dulmage, pinned, pineapple or combinations of these designs are available. Our
capacity ranges from 25mm up to 200mm depending on L/D ratio.
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Rubber Extrusion Screw
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Single Screw Extruder
Model
(Screw Dia)
mm
L/D
Ket-32
Ket-35
Ket-40
-32
-35
-40
Ket-45
Ket-50
(Capacity)
Kg/h
26-28
26-28
26-28
(Driving
Motor)
kw
5.5
7.5
11.20
-45
-50
26-28
28-30
15
18.75
50-55
65-70
Ket-55
-55
28-30
22.4
75-80
Ket-65A
Ket-65B
-65A
-65B
28-32
28-32
30
37.5
110-120
130-140
ket-75
Ket-90
Ket-100
-75
-90
-100
28-32
28-32
28-32
45
75
75-90
150-170
100-270
200-350
Ket-120
-120
28-32
90-110
300-450
20-25
30-35
40-45
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KAIVANYA EXTRUSION Engineering is the largest and by far the oldest
manufacturer of extrusion twin screws in India.
Based on this fact, kaivanya Factory machined the best plasticization satus &
blending quality are achieved.
New configured screws, which can be application to process PVC pipes &
profiles are developed by kaivanya Factory.
Also anticorrosion & wear resistant material are developed .
Polymer material can be sheared & compressed more softly in screw.
Extruders with twin-screw and short distance between screws are better than
other types, because of their high capacity and good thermal and mechanical
stress.
The powder mixing with chemical additives and melting with thermal and
mechanical energy in three zones (feed, compression and metering zone) and
because of gear pump and screw's pressure, converting to final product in
latest plate.
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This has enabled production of Twin Barrel with approximately twice
to thrice the service life of nitrided barrels at just 20% to 25 %
addition cost. This renders the economic efficiency factor irrelevant in
purchasing decisions. An additional benefit is the extended service
like of twin screw extruders with wear resistant barrels can be
operated at normal output for a longer period, without incurring
through put losses due to wear. Thus production costs are reduced
while competitiveness is improved.
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KAIVANYA EXTRUSTION TECHNIK
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We manufacture screws for both thermoplastic and thermosets, standard metering design
or QLT for improved melt homogeneity and mixing.
These can be hard faced, nitrided or hardened and nitrided with optional hard chrome
plating.
Whether you are manufacturing containers for packaging, duct joints for air
conditioning or automotive components, we have a screw design available to suit your
process for LDPE, HDPE, PP, PVC and more.
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The feed section establishes solids convey in the same way as a conventional screw.
At the beginning of the transition zone , a second flight is started.
This flight separates the solids channel from the melt channel.
As material progress down the transaction .
melting continues as the solids are pressed and sheared against the barrel, forming
a melt film.
The barrier flight moves under the melt film and the melt is collected in the solid
pellets and melted polymer are separated and different function are performed on
each.
The melt channel is deep , giving low shear and reducing the
possibility of overheating the melted polymer.
the solids channel becomes shallower, forcing the unmelted
pellets against the barrel for efficient frictional melting.
breakup of solids bed does not occur to stop this frictional melting .
the solids bed continues to get shallower and finally disappears into
the back side of the primary flight.
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KAIVANYA EXTRUSTION TECHNIK
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Blow molding is a manufacturing process by which hollow plastic parts are formed. In
general, there are three main types of blow molding: extrusion blow molding, injection
blow molding, and stretch blow molding. The blow molding process begins with melting
down the plastic and forming it into a parison or preform. The parison is a tube-like piece
of plastic with a hole in one end in which compressed air can pass through.
The parison is then clamped into a mold and air is pumped into it. The air pressure then
pushes the plastic out to match the mold. Once the plastic has cooled and hardened the
mold opens up and the part is ejected.
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The feed section establishes solids convey in the same ways as a conventional
screw.
At the beginning of the transition (compression) zone, a second flight is started.
This flight separates the solids channel from the melt channel.
As material progress down the transition, melting continues as the solids are
pressed and sheared against the barrel, forming a melt film, the barrier flight moves
under the melt film and the melt is collected in the solid pellets and melted polymer
are separated and different function are performed on each.
The melt channel is deep, giving low shear and reduction the possibility of
overheating the melted pellets against the barrel for efficient frictional melting,
breakup of solids bed does not occur to stop this frictional melting.
The solids bed continues to get shall over and finally disappears into the back side
of the primary flight.
Decompression zone. In this zone, about two-thirds down the screw, the channel
suddenly gets deeper, which relieves the pressure and allows any trapped gases
(usually moisture or air) to be drawn out by vacuum.
Second metering zone. This zone is like the first metering zone, but with greater
channel depth, and repressurizes the melt to get it through the resistance of the
screens and the die.
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KAIVANYA EXTRUSTION TECHNIK
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1 SURFACE-PREPARATION
2 THERMAL SPARY
4 Rolls
5 As sprayed screw
3 MIXING ROTORS
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6 Diamond Polish
8 Final Quality
7 SMALL SCREW
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Base Material
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Nitro alloy
AISI 4140
AISI 4340
Stainless Steels,17-4PH,316
Special alloy steel
Hard Facing Layer
1. KET183 (Ni/Cr/Boron/WC-35%)
2. KET 156 (Nickel- Cr/Boron)
3. KET163 (Nickel- Cr/Boron)
4. KET188 (Ni/Cr/Boron/WC-19%)
5. KET 900 (HOVF) TUGSTEN
88Wc/12 % Co
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Root Treatment
1. Nitriding
2. Chrome plating
3. Vapor Deposition
4. HVOF Thermal Spray
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Tool Steels
1. D2
2. H11,H13
3. V4,V9
4. CPM9V,CPM-S90V
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SCM440(1.7225)
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High Tensile Strength
Full hardening (56 HRc)
High Toughness
Flame Hardening
Chrome Plate
Nitride
Hard Face
SKD11(1.2379)
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Full Hardening (60 HRc)
Multi Purpose Screw
Good Abrasive Resistance
Good Corrosive Resistance (11%
Chromium)
Glass Fill 20%
SKD61(1.2344)
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Hot Work Tool Steel
Full Hardening (52 HRc)
Good Abrasive Resistance
High Temp. Hardness
Good Abrasive Resistance
Nitride
Stainless 17-4PH
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Full Hardening(48HRc)
High Toughness
High Temp.
Excellent Corrosive Resistance
Hard face
Nitride
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Special Alloy
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High Chemical Resistance
Inconel 625 Nickel Base (21%
Chromium9%molybdenum)
Hastelloy C276 Nickel Base (15%
chromium ,16% molybdenum
Hard Face
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Plasma Transfer ARC(PTA)
Screw Flight Built up
Cobalt (stlelite 12,48 HRc)
Nickel(colmonoy56,52 HRc,KET63)
Tungsten Carbine KET86,88 70,75
HRc
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Chromium Boride Hardness
Nickel Based Material
Hardness 49-56HRc
Anti-Abrasive /Corrosive
Tungsten Carbide Hardness
Nickel Based Material
Hardness 48-59HRc
Anti-Abrasive /Corrosive
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Element are Atomization to tiny
droplets, mixed to a certain
percentage.
Hot Isostatic pressing .
Fine & Uniform Micro Structure.
Good Toughness.
Stainless Steel Grade.
Nitride Process can enhance the PM
tool Steel hardness but it is not
common practice.
Companies Provided –
Bohler,Germany
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Nitride Surface
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Case Depth :0.2-0.4 mm
Hardness : 1000HV
Base Material
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Hardness 26-32 HRC
Iron Nitride
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Backing Steel
High Tensile strength Steel
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Chromium /Vanadium
950MPa Tensile Strength
630 Mpa Yield Strength
High temp. operating Condition
•Alloy liner
•Anti –abrasive
•Anti-Corrosive
•Base Material
•High Tensile Strength
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KET 56
KET63
KET 83
Chromium Boride/Carbide Chromium Boride/Carbide Tungsten Carbide
•Iron Base Material
•Hardness:- 64-69 HRc
•Anti- abrasive
•Glass Filled Application
•Iron Base Material
•Hardness:- 64-69 HRc
•Anti- abrasive
•Glass Filled Application
•Nickel Base Material
•Hardness 56-66 HRc
•Anti-abrasive /Corrosive
•High Wear application
KET 88
Premium Grade Tungsten
Carbide
Hardness 60-65 HRc
Excellent Anti-abrasive/corrosive
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KAIVANYA EXTRUSTION TECHNIK
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We hard-surface, straighten, machine, grind, and polish to precision tolerances. Special
hard-surfacing alloys are made with Nickel, Tungsten-Carbide and Molybdenum.
Screw Modification -- Engineering designed to your specifications. Our expert
consultation assures exact results.
Twin Screw Rebuilding -- Straight or Conical Twin Screws.
Barrel Manufacturing -- Extrusion and Injection molding barrel with bimetallic
inlays.
Barrel Resleeving and Honing -- Partial resleeves up to 24 inches or honing to an
even oversize dimension.
Components Building and Repair -- All replaceable components.
Chrome-Plating -- On site by our sister company Central Florida Plating.
Inspection Certificate -- All incoming and outgoing screws, barrels and components
are inspected and Rockwell tested for hardness and print accuracy.
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Barrel Rebuild/Repair
Screw Rebuild/Repair
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Rebuild the top of the flight with hard
facing (Satellite & Colmonoy)
Repair the internal thread
Repair the shank (drive section)
Repair the NPT thread
Repair the removable nose
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Re-sleeve the stroke section or
full length of the barrel with
standard bimetallic, carbide or
corrosion resistant liner
Repair the grooves within the
barrel and on the feed housing
section
Reline and repair the water jacket
for a rubber processing barrels
Pressure testing and acid flushing
for rubber processing barrels
Press-out broken screw from
barrel
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Rebuilding Process
Screw Re Joint
Key Way Spline Repair
O.D. Rebuilding
Flight Renovation
Crack Root
Special Coating
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Crack Fights
Straightening
Nose Resisted
Root Rebuilding
Nose Rethreading
Flight Rebuilding
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