May 2007

Engineering Case Histories

Case 38: Extruder wear prediction

An analysis can help avoid wear problems before they occur

Sofronas, A., Consulting Engineer

Extruders are used in the processing industries to develop products for use by their customers. Fail the extruder and the operation can come to an abrupt halt, usually with significant production losses. Analyzing the extrusion process is extremely complex; however, plant engineers are frequently called on to troubleshoot extruder wear problems and talk with the manufacturers. Plants usually take screw wear measurements during routine maintenance on critical extruders, some 20,000 hp and larger. The author had accumulated a 20-year database on extruder wear histories and failures with various products. To better utilize this historical database and help predict the wear life or the causes

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