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Nov 21,2024When the molten pipe slowly flows out of the die head of the extruder, it is like a flowing hot river, full of infinite possibilities. However, in order to solidify this hot river into a pipe with a specific shape and size, the cooling and shaping process is particularly important. At the end of the extrusion line, a carefully designed cooling zone greets each new pipe. Here, cooling water or cold air is used as a cooling medium to quickly take away the heat on the surface of the pipe through direct contact or indirect spraying, so that its temperature drops rapidly, thereby realizing the transition from molten state to solid state.
The core of the cooling and shaping process lies in the precise control of the cooling speed and cooling method. Too fast cooling speed may cause the internal stress of the pipe to increase, affecting its long-term performance; while too slow cooling speed may cause the shape of the pipe to be unstable and the dimensional deviation to increase. Therefore, in the pipe extrusion line, the design and operation of the cooling zone often need to be combined with specific factors such as pipe material, wall thickness, diameter, etc., and detailed parameter adjustment and optimization are required.
The key to the cooling and shaping process being able to have a significant impact on the physical properties of the pipe is its optimization of the internal structure of the pipe. During the cooling process, as the temperature drops rapidly, the molecular chains inside the pipe gradually tend to stabilize, reducing the problems of molecular chain relaxation and uneven orientation caused by high temperature. This optimization of the molecular chain structure enables the pipe to exhibit more excellent performance in terms of strength, toughness, corrosion resistance, etc.
When the pipe is in a molten state, the molecular chains inside it are in a highly disordered state, and the interaction between molecules is weak. During the cooling process, as the temperature decreases, the molecular chains begin to gradually shrink and tend to be arranged in an orderly manner. This orderly arrangement not only enhances the interaction between molecules, but also makes the overall structure of the pipe more compact and stable. At the same time, the directional arrangement of the molecular chains during the cooling process can also reduce the deformation and crack propagation of the pipe when it is subjected to force, thereby improving its strength and toughness.
The cooling and shaping process can also further control the molecular chain structure inside the pipe by adjusting parameters such as the temperature and flow rate of the cooling medium. For example, by reducing the temperature of the cooling medium or increasing the flow rate, the cooling speed inside the pipe can be accelerated, so that the molecular chains inside it tend to stabilize faster. This precise control capability makes the cooling and shaping process extremely flexible and customizable in improving the physical properties of the pipe.
The cooling and shaping process is widely and deeply used in pipe extrusion production lines. From common PVC drainage pipes, PE water supply pipes to high-end glass fiber reinforced plastic composite pipes, PPR hot water pipes, etc., almost all types of plastic pipes need to be processed by the cooling and shaping process. This process not only ensures the shape and dimensional accuracy of the pipe, but also significantly improves its physical properties, enabling it to meet the high standards of pipe quality in different fields.
The cooling and shaping process also faces some challenges. First, with the continuous upgrading of pipe materials and structures, the requirements for cooling and shaping processes are also getting higher and higher. For example, for some new polymer materials, their molecular chain structure and thermal behavior may be significantly different from traditional plastic materials, so more sophisticated cooling control strategies are required. Secondly, with the expansion of production scale and the improvement of automation, higher requirements are also placed on the stability and reliability of the cooling and shaping process. How to ensure that the cooling and shaping process can always maintain stable performance output during high-speed and continuous production is a major challenge facing the current pipe extrusion production line.
Faced with these challenges, manufacturers and researchers of pipe extrusion production lines are constantly exploring and innovating. On the one hand, they have achieved real-time monitoring and precise control of the cooling and shaping process by introducing advanced sensors and control systems. These systems can monitor parameters such as temperature, shape and size of the pipe in real time, and automatically adjust parameters such as temperature and flow rate of the cooling medium according to changes in these parameters, thereby ensuring the stability and reliability of the cooling and shaping process.
On the other hand, they are also constantly exploring new cooling media and cooling methods. For example, some researchers are trying to use cryogenic media such as liquid nitrogen for rapid cooling to further improve the physical properties and production efficiency of the pipe. At the same time, they are also studying how to optimize the cooling effect and reduce energy consumption by changing the structure and layout of the cooling zone.
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