Uneven discharge from the die head of the film blowing machine is one of the common problems in the production process of plastic film. This problem not only affects the flatness and thickness uniformity of the film, but may also lead to reduced production efficiency and increased costs. Therefore, solving the problem of uneven discharge from the die head of the film blowing machine is of great significance to improving product quality and production efficiency.
Uneven discharge caused by unreasonable flow channel design inside the die head
The flow channel design defects inside the die head are one of the key factors causing uneven discharge distribution. The different number of flow channels causes differences in the fluid properties of each part of the die head, which in turn causes differences in material flow distribution. Improper flow channel design may have an adverse effect on the flow characteristics and distribution of the material, resulting in uneven flow or uneven flow rate of the material inside the mold, which in turn causes uneven discharge. Reasonable flow channel design can improve product quality and output. Common deficiencies in the design include blind spots and uneven flow rate.
In order to optimize the flow channel design, the following methods can be taken:
1. Adjust the shape of the flow channel: By adjusting the shape and size of the flow channel, ensure that the material flows more smoothly inside the mold, so that the flow rate is more balanced.
2. Add a guide plate: By installing a guide plate inside the flow channel, the material can be guided to flow along the predetermined path, thereby avoiding dead corners and uneven flow rates.
In the design process of the die head, we must deeply consider the flow characteristics and process requirements of the material to ensure the rationality and smoothness of the flow channel design, thereby improving the uniformity of the discharge
Uneven discharge caused by loose or damaged die head components
Loose or damaged die head components (such as bolts, gaskets, etc.) may cause uneven discharge. Since the die head components are generally made of stainless steel, there are inevitably some vulnerable parts in the die head. The sealing and stability of the die head will be affected by the looseness or damage of these components, which may cause leakage or deviation of the material when it flows inside the die head, resulting in uneven discharge.
In order to check and repair the looseness or damage of the mold head, we can consider the following methods:
1. It is necessary to conduct regular inspections of the mold head parts. Once any loose or damaged parts are found, they should be replaced or fixed immediately.
2. Use special tools: Use these tools to disassemble and install the head part of the mold to ensure its sealing and stability.
In the process of repairing the mold head parts, the operating guidelines and safety standards must be strictly followed to ensure that the mold head can work normally after the repair and achieve the predetermined discharge effect.
The influence of inconsistent plasticization degree of materials on the uniformity of discharge
The uneven plasticization degree of the material before entering the die head will also affect the uniformity of the discharge. Therefore, the mold cavity must be fully heated and cooled to achieve the required plasticization temperature. Whether the plasticization degree is insufficient or excessive, it may cause the material to flow obstructed or blocked inside the mold, which will have an adverse effect on the uniformity of the discharge.
In order to ensure the consistency of material plasticization, we can implement the following strategies:
1. Adjust the temperature, pressure and duration of melting: Based on the unique properties of the material and process requirements, adjust the temperature, pressure and duration of melting to ensure that the material can reach the appropriate plasticization level during the melting process.
2. It is crucial to regularly inspect and clean the melting system to ensure that the system can operate smoothly and stably.
By implementing the above methods, we can ensure that the material reaches the appropriate plasticization level before entering the die head, thereby enhancing the balance of the discharge.
Uneven discharge caused by unstable parameters during operation
During operation, the discharge of the die head may be uneven due to the instability of factors such as pressure and temperature. Due to the structure of the mold itself, factors such as demolding force, friction force and friction factor cause a certain degree of contact between the various parts of the die head, resulting in different stresses at various positions. The fluidity and distribution of the material will be affected by the fluctuations of these parameters, resulting in uneven discharge.
In order to ensure the stability of operating parameters, we can consider the following strategies:
1. Use an automated control system: The system can observe and adjust key parameters such as pressure and temperature in real time to ensure that these parameters are always within the predetermined range.
2. Regularly calibrate and maintain the instrument to ensure the accuracy and stability of the instrument.
In addition, operators need to receive special professional training to master the correct operating skills to ensure that all parameters can be accurately controlled during operation, thereby improving the uniformity of the discharge.
The impact of changes in the internal surface roughness of the die head after long-term use on the discharge
After a long period of use, the surface roughness of the die head may change due to corrosion of the material and mechanical wear. Affect the film thickness distribution to a certain extent. Such changes may affect the flow characteristics of the material and the homogeneity of the film, resulting in uneven discharge.
In order to solve the problem of changes in the internal surface roughness of the die head, we can consider the following solutions:
1. Polishing process: Perform polishing operations inside the die head to restore its original smoothness and enhance the flow characteristics of the material.
2. About the repair or replacement of the die head: For those die heads that are severely worn or corroded, corresponding repairs or replacements must be carried out to ensure that they can work normally and achieve the expected discharge effect.
At the same time, we should emphasize the necessity of regular maintenance and upkeep of the die head to extend its service life. By regularly cleaning, inspecting and maintaining the die head, we can identify and solve possible problems in a timely manner, thereby ensuring that the die head can work properly and ensure the uniformity of the discharge.
In summary, in order to solve the problem of uneven discharge of the film blowing machine die head, the key solutions and methods include optimizing the flow channel design, checking and repairing the looseness or damage of the die head components, ensuring the consistency of the plasticization degree of the material, stabilizing the operating parameters, and dealing with the changes in the roughness of the internal surface of the die head. In addition, in actual use, attention should also be paid to the rationality of the die head structure and maintenance work. By implementing these strategies and means, we can significantly enhance the discharge consistency of the film blowing machine die head, thereby optimizing the quality of the product and increasing the benefits of production. At the same time, we should emphasize the key role of preventive measures and regular inspections in avoiding the problem of uneven materials. In addition, due to the fast feeding speed of the film blowing machine die head, a certain time interval needs to be ensured when cleaning the die head to reduce the influence of residual moisture. In order to ensure that the film blowing machine die head can work stably for a long time and produce high-quality products, we must increase daily maintenance and care.
