Extrusion is one of the most widely used manufacturing processes. Deployed in many industries, extrusion can be described as a procedure for manufacturing a product by compelling the material through an aperture or die to make a shape which is mostly long and straight. Extrusion is a way to make products of a desired cross-sectional shape. In this process the material (extruded) is squeezed in an extruder with the help of a hydraulic or mechanical powered press to produce various shapes, for example, cylindrical, rectangular, and tubular (hollow, pipe-like), U Channel, D Section, P Shape, E Shape, T Shapes, or any other desired and complex shape. Extruded rubber products and components are utilized in many industrial, mechanical and household applications. Extrusions are widely used in the production of tubes and hollow pipes. Hose pipes, rubber cord, rubber strip, simple solid or hollow profiles, food grade tubing, silicone sleeves, extruded rubber gaskets and seal, door and window seals, etc. are some more examples.
Rubber extrusion process
Extrusions can be manufactured in various materials from rubber, thermoplastic elastomer or thermoplastics.
The procedure of extrusion essentially requires an extrusion machine or extruder. The profile die is implanted at the head of the machine by means of a winded and secured wheel. The die is heated up or cooled down with a peripheral heating and cooling source to help polymer stream in the early stages of setting up to run. So fundamentally, extrusions are parts constrained through a die of the required cross-area under pressure of an extrusion machine or extruder. Profiles are fabricated in straight lengths or coils relying upon the extent of profile and can be sliced to length to suit client prerequisites.
Rubber extrusions vs. other extrusions
Producers of rubber extrusion products first create a die in the state of the required cross-area and then pressurize the rubber material through the die. The immense pressure under which this happens makes the rubber delicate and flexible, empowering makers to shape it suitably. In the wake of forming the rubber, it is now vulcanized, thus solidifying into the ideal and desired shape.
Plastic is extruded fairly uniquely in contrast to rubber. Amid plastic extrusion, the plastic is smelted and afterward constrained through the die. After the die has molded the liquid plastic into the ideal shape, it cools into a strong form and is cut to the proper length.
The primary quality that separates plastic from rubber is that plastic can be melted and reused. Rubber, once cured, remains solid.
As far as aluminum or metal extrusions are concerned, they require additional number of steps in the extrusion process. Drilling or cutting of finished rubber or plastic extrusion products is much easier compared to their metal counterparts.
At times, a combination of different materials is co extruded to accomplish a blend of performance properties. This completely wipes out the requirement of any assembling of finished products. As an additional and favorable property, plastic produces steady shading all through. This limits the presence of potential cracks or scuffs that could be noticeable on a composed surface.
Rubber extrusion things need to consider
The most significant procedure parameters are pressure of head, speed of extrusion and temperature. They are the best pointers of how well or how inadequately the extruder performs. Procedure issues, as a rule, are first turn out to be clear from the head pressure and temperature readings.
Other significant extrusion procedure parameters are:
- Design of the die
- Proper land length
- Land length ratio
- Draw down
- Screw speed
- Motor load
- Barrel temperatures
- Die temperatures
- Cooling rates
- Vacuum level in vented extrusion
- Designing for sensitive materials
These parameters relate just to the extruder. In any case, there are a lot more procedure parameters for the whole extrusion line and this, obviously, relies upon its particular segments. Significant parameters for any extrusion line are:
- Line speed
- Dimensions of the extruded product
- Line tension
Numerous different variables can impact the extrusion procedure, for example, surrounding temperature, humidity, air flows around the extruder, and plant voltage fluctuations, among others.
Rubber extrusion application or product lines
Depending upon the shapes, sizes, and the material used, rubber extrusions are used in a variety of applications. Silicone extrusion products or components are used for applications where shape retention and mechanical strength are required in extreme or harsh operating conditions. Neoprene/Chloroprene products are highly resistant to oil, petroleum, ozone, heat, and sunlight. EPDM or Ethylene propylene diene monomer, exhibits outstanding heat, ozone, weather, and heat resistance and has excellent electrical insulating properties. The natural rubber has ability to absorb vibration makes natural rubber ideal for use as dampeners. With resistance to organic acids and alcohols, it’s also found in food and beverage processing applications. Low smoke, flame & toxicity EPDM Rubber Products are ideal for the mass transit industry. Fluoroelastomers are used in a variety of applications, which include fuel system seals and hoses, O-rings, gaskets, and extrusions.
At Accurate Rubber Corporation, when we take a gander at each of our extrusion venture for clients, we find it to be a different task with new shapes, sizes, and materials. Be that as it may, while each undertaking is interesting, the procedures and skill developed by us for long periods of diligent work imply that we can give clients the parts they require for their individual prerequisites.
We highly esteem great and cordial client service. In the event that our clients are searching for product accessibility, unwavering quality and efficient response to their solicitations. Please contact us if you have any questions about your extruded silicone rubber gasket project requirements.