Skip to content
Licensed Unlicensed Requires Authentication Published by De Gruyter April 6, 2013

Melting Quality of Polymers in Internal Mixer Diagnosed by Ultrasound

  • C.-C. Cheng , H. Banakar , B.-T. Ooi and C.-K. Jen

Abstract

Real-time, non-intrusive and non-destructive ultrasonic technology has been used to monitor the melting process in an internal mixer. Visual observation, mechanical torque measurement, and ultrasonic signatures, such as amplitude and time delay of transmission and reflection echoes were used for the diagnosis of the melting process of low density polyethylene (LDPE). Phenomena during the melting process, including phase change from solid to melt, partially melted pellets, air bubbles inside the melt, were successfully monitored by ultrasound. The ultrasonic signatures were able to determine when the polymer has melted completely. The method of moving standard deviation (MSD) was applied to establish the melting completion timing accurately. Higher temperature of mixing chamber and faster rotation speed of blades reduced melting completion period, indicated by MSD of ultrasonic signatures. The presented ultrasonic technique can be utilized to optimize the melting process.


Mail address: Chin-Chi Cheng, Dept. of Electrical Engineering, Hsiuping Institute of Technology, 11, Gongye Rd., Da-Li City, Taichung, Taiwan, 412-80. E-mail:

References

Bousmina, M., et al., “Determination of Shear Rate and Viscosity from Batch Mixer Data”, J. Rheol.43, 415433(1999) DOI: 10.1122/1.551044Search in Google Scholar

Brown, E. C., et al., “Ultrasound: A Virtual Instrument Approach for Mornitoring of Polymer Melt Variables”, J. Reinf. Plast. Compos., 18, 331338(1999)Search in Google Scholar

Cheng, C. C., et al., “Real-time Diagnosis of Micro Powder Injection Molding Using Intergrated Ultrasonic Sensors”, Int. Polym. Proc., 22, 140145(2007)Search in Google Scholar

Gendron, R., et al., “Ultrasonic Behavior of Polymer Blends”, Polym. Eng. Sci., 35, 7991(1995) DOI: 10.1002/pen.760350111Search in Google Scholar

Ghoreishy, M. H. R., Nassehi, V., “Modeling the Transient Flow of Rubber Compounds in the Dispersive Section of an Internal Mixer with Slip-stick Boundary Conditions”, Adv. Polym. Tech.16, 4568(1997) DOI: 10.1002/(SICI)1098-2329(199721)16:1<45::AID-ADV5>3.0.CO;2-JSearch in Google Scholar

Goodrich, J. E., Porter, R. S., “A Rheological Interpretation of Torque-Rheometer Data”, Polym. Eng. Sci.7, 4551(1967) DOI: 10.1002/pen.760070112Search in Google Scholar

Hayslett, H. T.: “Statistics Made Simple”, Doubleday Publisher, New York(1968)Search in Google Scholar

Jen, C. K., et al., “Experimental Evaluation of Clad Metallic Buffer Rods for High Temperature Ultrasonic Measurements”, Nondestructive Testing & Evaluation Int'l, 33, 145153(2000)Search in Google Scholar

Jongen, T.Characterization of Batch Mixers Using Numerical Flow Simulations”, AIChE J., 46, 21402150(2000) DOI: 10.1002/aic.690461107Search in Google Scholar

Michaeli, W., Starke, C., “Ultrasonic Investigations of the Thermoplastics Injection Moulding Process”, Polym. Test., 24, 205209(2005) DOI: 10.1016/j.polymertesting.2004.08.009Search in Google Scholar

Piche, L., et al., U.S. Patent 4 754 645 (1988)Search in Google Scholar

Qin, S., Badgewell, T., “An Overview of Industrial Model Predictive Control Technology”, Chemical Process Control, 93, 232256(1997)Search in Google Scholar

Serpe, G., et al., “Morphology-processing Relationships in Polyethylene-polyamide Blends”, Polym. Eng. Sci.30, 553565(1990) DOI: 10.1002/pen.760300908Search in Google Scholar

Shih, C. K., et al., “Rheological Properties of Multicomponent Polymer Systems Undergoing Melting or Softening during Compounding”, Polym. Eng. Sci.31, 16701673(1991) DOI: 10.1002/pen.760312307Search in Google Scholar

Sun, Z., et al., “A Prototype Ultrasonic System for Monitoring Polymer Mixing Process on an Internal Mixer”, Proceeding Int. Conf. on Dynamics, Instrumentation and Control, FE01-2, Nanjing (2004)10.1142/9789812702289_0045Search in Google Scholar

Sun, Z., et al., “Application of Ultrasound in the Determination of Fundamental Extrusion Performance: Monitoring of Filler Dispersion during Twin Screw Extrusion”, Proceeding Polymer Processing Soc. Conf., 262, Seoul (2004)Search in Google Scholar

Tatibouet, J., Piche, L., “Ultrasonic Investigation of Semi-crystalline Polymers: Study of Poly (ethylene terephthalate)”, Polymer, 32, 31473153(1991) DOI: 10.1016/0032-3861(91)90135-6Search in Google Scholar

Wang, H., et al., “On-line Ultrasonic Monitoring of the Injection Molding Process”, Polym. Eng. Sci., 37, 363376(1997) DOI: 10.1002/pen.11679Search in Google Scholar

Zalc, J. M., et al., “Characterization of Flow and Mixing in an SMX Static Mixer”, AIChE J., 48, 427436(2002) DOI: 10.1002/aic.690480303Search in Google Scholar

Received: 2008-02-12
Accepted: 2009-08-06
Published Online: 2013-04-06
Published in Print: 2009-11-01

© 2009, Carl Hanser Verlag, Munich

Downloaded on 3.2.2023 from https://www.degruyter.com/document/doi/10.3139/217.2166/html
Scroll Up Arrow