New materials, new designs and intelligent control systems for extruder screws

1. New materials

High-performance alloys
38CrMoAl: This is the earliest material for screws and threaded components. It is widely used because of its low price and convenient machining. However, the domestic extruder industry has developed rapidly in the past 30 years, and equipment parameters have been greatly improved. 38CrMoAl can no longer keep up with equipment requirements.
W6Mo5Cr4V2 high-speed steel (6542): It was widely used after it was produced in the United States in 1989. It is currently widely used in the industry and is a mainstream product for the world.
WR5: In view of the wear resistance and high temperature resistance required by the current extruder, the WR5 material can, to a certain extent, cope well with the high temperature and high wear problems encountered during the manufacturing and processing of the extruder.
EFZD alloy steel, C53 alloy steel, SKH series (such as SKH-9/51, SKH-55, SKH-59), W18Cr4V, YXMI alloy steel, SKD61, SKD11 alloy steel: These high-performance alloy steel full-hard screws are also widely used in the field of extruders.
GH113 (New No. 3 Steel): Suitable for the production of high-temperature products such as tetrafluoroethylene (F46) and Teflon.
Stainless steel: Imported stainless steel materials such as Hitachi HPM38, S136, SUS440, 9cr18mov are also used to manufacture screws.
Ceramic composite materials: Although ceramic composite materials are relatively rarely used in extruder screws, their performance advantages in high temperature resistance and wear resistance are worthy of attention. With the advancement of materials science, the application of ceramic composite materials in the field of extruder screws may be more extensive in the future.

2. New design

Spiral groove optimization: By optimizing the design of the spiral groove, the flow state of the material can be improved and the extrusion efficiency can be improved. For example, adding shunt elements such as pins to the screw can disrupt the material flow, reduce temperature fluctuations and pressure fluctuations, and improve extrusion quality.
Modular design: The modular design makes it easier to disassemble and replace the screw, reducing maintenance costs. At the same time, the modular design is also convenient for flexible adjustment according to production needs, improving the versatility and adaptability of the equipment.

3. Intelligent control system

Real-time temperature monitoring and adjustment: Through the intelligent heating system, the working temperature of the screw can be monitored and adjusted in real time to ensure that the material maintains a stable temperature state during the extrusion process. This helps to improve product quality and production efficiency.
Real-time pressure monitoring and adjustment: The pressure sensor monitors the pressure changes during the working process of the screw in real time and adjusts it as needed. This helps to avoid problems such as equipment damage or material leakage caused by excessive pressure.
Real-time speed monitoring and adjustment: The speed sensor monitors the speed of the screw in real time and adjusts it accurately according to production needs. This helps to maintain a stable extrusion speed and improve product quality and production efficiency.
Intelligent alarm and diagnosis system: Through the intelligent alarm function, the operating status of the equipment can be monitored in real time, and an alarm will be issued in time when a fault occurs. At the same time, the system can also provide troubleshooting methods and online modification of the internal parameters of the driver, which helps to quickly restore the normal operation of the equipment.
Remote monitoring and maintenance: Through the remote debugging function, users can access the Internet in any corner of the world to perform remote startup, fault handling, software upgrades and other operations. This greatly improves the maintenance efficiency and convenience of the equipment.