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Preface to the Fourth Edition | |
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Preface to the First Edition | |
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Introduction | |
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Basic Process | |
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Scope of the Book | |
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General Literature Survey | |
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History of Polymer Extrusion | |
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References | |
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Extrusion Machinery | |
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Different Types of Extruders | |
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The Single Screw Extruder | |
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Basic Operation | |
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Vented Extruders | |
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Rubber Extruders | |
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The Multiscrew Extruder | |
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The Twin Screw Extruder | |
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The Multiscrew Extruder with More Than Two Screws | |
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The Gear Pump Extruder | |
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Disk Extruders | |
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Viscous Drag Disk Extruders | |
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The Elastic Melt Extruder | |
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Overview of Disk Extruders | |
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Ram Extruders | |
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Single Ram Extruders | |
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Multi Ram Extruder | |
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Appendix 2.1 | |
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References | |
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Extruder Hardware | |
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Extruder Drive | |
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AC Motor Drive System | |
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DC Motor Drive System | |
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Hydraulic Drive System | |
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Comparison of Various Drive Systems | |
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Reducer | |
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Constant Torque Characteristics | |
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Thrust Bearing Assembly | |
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Barrel and Feed Throat | |
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Feed Hopper | |
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Extruder Screw | |
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Die Assembly | |
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Screens and Screen Changers | |
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Heating and Cooling Systems | |
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Electric Heating | |
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Fluid Heating | |
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Extruder Cooling | |
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Screw Heating and Cooling | |
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References | |
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Instrumentation and Control | |
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Instrumentation Requirements | |
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Most Important Parameters | |
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Pressure Measurement | |
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The Importance of Melt Pressure | |
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Different Types of Pressure Transducers | |
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Mechanical Considerations | |
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Specifications | |
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Comparisons of Different Transducers | |
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Temperature Measurement | |
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Methods of Temperature Measurement | |
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Barrel Temperature Measurement | |
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Stock Temperature Measurement | |
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Other Measurements | |
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Power Measurement | |
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Rotational Speed | |
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Extrudate Thickness | |
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Extrudate Surface Conditions | |
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Temperature Control | |
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On-Off Control | |
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Proportional Control | |
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Controllers | |
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Time-Temperature Characteristics | |
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Tuning of the Controller Parameters | |
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Total Process Control | |
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True Total Extrusion Process Control | |
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References | |
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Process Analysis | |
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Fundamental Principles | |
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Balance Equations | |
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The Mass Balance Equation | |
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The Momentum Balance Equation | |
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The Energy Balance Equation | |
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Basic Thermodynamics | |
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Rubber Elasticity | |
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Strain Induced Crystallization | |
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Heat Transfer | |
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Conductive Heat Transfer | |
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Convective Heat Transfer | |
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Dimensionless Numbers | |
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Viscous Heat Generation | |
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Radiative Heat Transport | |
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Basics of Devolatilization | |
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Devolatilization of Particular Polymer | |
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Devolatilization of Polymer Melts | |
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Appendix 5.1 | |
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References | |
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Important Polymer Properties | |
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Properties of Bulk Materials | |
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Bulk Density | |
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Coefficient of Friction | |
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Particle Size and Shape | |
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Other Properties | |
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Melt Flow Properties | |
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Basic Definitions | |
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Power Law Fluid | |
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Other Fluid Models | |
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Effect of Temperature and Pressure | |
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Viscoelastic Behavior | |
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Measurement of Flow Properties | |
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Thermal Properties | |
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Thermal Conductivity | |
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Specific Volume and Morphology | |
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Specific Heat and Heat of Fusion | |
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Specific Enthalpy | |
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Thermal Diffusivity | |
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Melting Point | |
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Induction Time | |
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Thermal Characterization | |
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Polymer Property Summary | |
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References | |
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Functional Process Analysis | |
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Basic Screw Geometry | |
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Solids Conveying | |
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Gravity Induced Solids Conveying | |
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Drag Induced Solids Conveying | |
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Plasticating | |
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Theoretical Model of Contiguous Solids Melting | |
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Other Melting Models | |
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Power Consumption in the Melting Zone | |
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Computer Simulation | |
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Dispersed Solids Melting | |
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Melt Conveying | |
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Newtonian Fluids | |
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Power Law Fluids | |
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Non-Isothermal Analysis | |
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Die Forming | |
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Velocity and Temperature Profiles | |
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Extrudate Swell | |
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Die Flow Instabilities | |
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Devolatilization | |
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Mixing | |
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Mixing in Screw Extruders | |
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Static Mixing Devices | |
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Dispersive Mixing | |
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Backmixing | |
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Appendix 7.1 | |
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Appendix 7.2 | |
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Appendix 7.3 | |
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References | |
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Practical Applications | |
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Extruder Screw Design | |
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Mechanical Considerations | |
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Torsional Strength of the Screw Root | |
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Strength of the Screw Flight | |
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Lateral Deflection of the Screw | |
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Optimization for Output | |
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Optimizing for Melt Conveying | |
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Optimizing for Plasticating | |
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Optimizing for Solids Conveying | |
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Optimizing for Power Consumption | |
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Optimum Helix Angle | |
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Effect of Flight Clearance | |
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Effect of Flight Width | |
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Single Flighted Extruder Screws | |
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The Standard Extruder Screw | |
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Modifications of the Standard Extruder Screw | |
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Devolatilizing Extruder Screws | |
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Functional Design Considerations | |
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Various Vented Extruder Screw Designs | |
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Vent Port Configuration | |
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Multi-Flighted Extruder Screws | |
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The Conventional Multi-Flighted Extruder Screws | |
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Barrier Flight Extruder Screw | |
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Mixing Screws | |
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Dispersive Mixing Elements | |
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Distributive Mixing Elements | |
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Scale-Up | |
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Common Scale-Up Factors | |
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Scale-Up for Heat Transfer | |
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Scale-Up for Mixing | |
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Comparison of Various Scale-Up Methods | |
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Rebuilding Worn Screws and Barrels | |
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Application of Hardfacing Materials | |
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Rebuilding of Extruder Barrels | |
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References | |
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Die Design | |
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Basic Considerations | |
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Balancing the Die by Adjusting the Land Length | |
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Balancing by Channel Height | |
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Other Methods of Die Balancing | |
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Film and Sheet Dies | |
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Flow Adjustment in Sheet and Film Dies | |
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The Horseshoe Die | |
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Pipe and Tubing Dies | |
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Tooling Design for Tubing | |
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Blown Film Dies | |
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The Spiral Mandrel Geometry | |
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Effect of Die Geometry on Flow Distribution | |
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Summary Spiral Mandrel Die Design Variables | |
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Profile Extrusion Dies | |
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Coextrusion | |
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Interface Distortion | |
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Calibrators | |
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References | |
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Twin Screw Extruders | |
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Introduction | |
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Twin versus Single Screw Extruder | |
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Intermeshing Co-Rotating Extruders | |
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Closely Intermeshing Extruders | |
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Self-Wiping Extruders | |
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Intermeshing Counter-Rotating Extruders | |
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Non-Intermeshing Twin Screw Extruders | |
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Coaxial Twin Screw Extruder | |
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Devolatilization in Twin Screw Extruders | |
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Commercial Twin Screw Extruders | |
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Screw Design Issues for Co-Rotating Twin Screw Extruders | |
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Scale-Up in Co-Rotating Twin Screw Extruders | |
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Overview Twin Screw Extruders | |
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References | |
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Troubleshooting Extruders | |
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Requirements for Efficient Troubleshooting | |
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Instrumentation | |
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Understanding of the Extrusion Process | |
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Collect and Analyze Historical Data (Timeline) | |
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Team Building | |
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Condition of the Equipment | |
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Information on the Feed Stock | |
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Tools for Troubleshooting | |
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Temperature Measurement Devices | |
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Data Acquisition Systems (DAS) | |
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Light Microscopy | |
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Thermochromic Materials | |
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Thermal Analysis | |
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Miscellaneous Tools | |
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Systematic Troubleshooting | |
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Upsets versus Development Problems | |
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Machine Related Problems | |
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Polymer Degradation | |
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Extrusion Instabilities | |
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Air Entrapment | |
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Gel Problems | |
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Die Flow Problems | |
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References | |
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Modeling and Simulation of the Extrusion Process | |
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Introduction | |
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Background | |
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Analytical Techniques | |
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Numerical Methods | |
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Remeshing Techniques in Moving Boundary Problems | |
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Rheology | |
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Simulating 3-D Flows with 2-D Models | |
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Simulating Flows in Internal Batch Mixers with 2-D Models | |
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Simulating Flows in Extrusion with 2-D Models | |
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Simulating Flows in Extrusion Dies with 2-D Models | |
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Three-Dimensional Simulation | |
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Simulating Flows in the Banbury Mixer with 3-Dimensional Models | |
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Simulating Flows in Extrusion Dies with 3-Dimensional Models | |
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Simulating Flows in Extrusion with 3-Dimensional Models | |
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Static Mixers | |
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Conclusions | |
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References | |
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Index | |