Address : Shed No-66 & 74, Parishram Estate,
Nr. Janta Nagar, Ramol, CTM, Ahmedabad, Gujarat, India-382449.

Screw Barrel Repairing

Screw Barrel Repairing

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Repair/Rebuild Services for screw barrel

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* flight repairs
* root and radius repairs
* full-length coatings on extrusion and injection screws.
* Barrel repairing, honing

Contact: +91 8128381431, 9924225214, +917874581018
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Flight repairs are performed using a multi-step welding process utilizing plasma-transferred arc welding with a complete quality control system.
Root and Radius repairs, as required, are made with compatible base metals or hard surfaces for value-added protections against future damage.
Full-length coatings offer additional protection to extruders processing fiberglass or talc-reinforced resins.

When to Replace an Extrusion Barrel

As barrels wear the clearance between the screw flight and barrel wall increases, especially in the high-pressure areas of the barrel. Buying a new screw for a worn barrel does not solve the clearance problem. It may make it better, but it is not a fix for a worn barrel.
Since barrels only wear in high-pressure areas or where the fusion of the polymer takes place, measuring the end of the barrel ID does not tell the whole story of wear.
A bore gauge should be used to measure wear all along the barrel. Keep in mind that the screw wear has to be taken into account with Barrel wear to determine the total clearance.

If you don't know what your wear dimensions are, we have the tools and can measure your barrels.
Contact: +91 8128381431, 9924225214, +917874581018
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Repairing Extrusion Barrels

In the injection molding markets, it is common to "re-sleeve" the high-pressure end of the barrel. The last 20" or so of the barrel is re-sleeved. The screw is reciprocating back and forth.
Why don't we recommend lining barrels in extrusion?
The barrels are longer. Example: 3.5" x 24:1 L/D is approximately 80 long, not including the feed throat. In extrusion, unlike injection molding, the screw only turns one direction. When several sleeves (sleeves 12-15" long) are heat shrunk in the barrel. They do not match up evenly. To hone or grind out the inside diameter of the barrel would take hours and hours to perform, resulting in high costs. The hone will follow the highs and lows of the barrel and not yield a straight bore. All the time, the hone is wearing or reducing the thickness of the bimetallic liner that has been inserted.

Some customers in blown film applications have been led to believe they can get at least another 6 months to 1 year out of the barrel. WRONG!

Problems that may pop up later with barrel rebuilds:

The sleeves can shrink and spin.
The sleeves can weld to the screw flights if too tight. (caused by highs and lows of honing barrel)
They can have poor heat transfer from heater bands, due to different metals and space between the OD of the barrel tube and the ID of new sleeves.

Injection Molding Screw Barrel repairing:

The economics are more favorable for repairing injection molding barrels, particularly since repair often involves relining only a short portion of the entire barrel. Typically this short sleeve is installed at the discharge or stroke end of the barrel near the check ring, an area that is especially subject to wear and resulting leakage. Such leakage makes it difficult to control shot size. As a rule of thumb, when the wear in an injection barrel reaches 0.020 in., it is time to repair or replace the barrel. For critical molding applications, the cutoff point may be as low as 0.003 in. In, by contrast, the level of wear can range up to 0.250 in. for very select applications.

Nowadays, many injection barrels that might have been repaired in the past are being replaced instead. With modern manufacturing methods and productivity improvements, the cost of new bimetallic barrels has come down, and the performance demands placed on the barrels are much greater. Where once pressures of 20,000 psi were standard, today 35,000 psi is common. In addition, part requirements dimensional tolerances, avoidance of flash, and other quality parameters have become more stringent.

The process of repairing a barrel requires the removal of a portion of its inner wall the metal surrounding the bore or screw channel and replacing it with a newly manufactured, thin-walled bimetallic sleeve or liner. It is absolutely essential that there be an extremely tight metal-to-metal fit between the liner and the original steel. Raj Engineering Works know how to accomplish this. A repair by an inexperienced company or a corner-cutting repair can adversely affect the molding or extrusion process and the quality of finished products.
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