International Journal of JOURNAL Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 3, May - June (2013), pp. 94-99 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

FORMULATION OF FIELD DATABASED MODEL: A CASE STUDY AT PVC PIPE MANUFACTURING INDUSTRIES
Vikhar A D* Dr. Modak J.P#

* Ex. Associate Professor in Mechanical Engineering, (SGDCOE), Jalgaon (MS), Faculty in Mechanical Engineering, DTE, Government of Maharashtra, Government Polytechnic, Khamgaon. # Ex. Head, Dept. of Mech. Engg., VNIT, Nagpur, Emeritus Professor in Mechanical Engineering, Dean (R & D), Priyadarshini College of Engineering, Nagpur.

ABSTRACT Extrusion of PVC pipe is a steady-state process for converting a thermoplastic raw material to a finished. The raw material is usually in the form of plastic pellets or powder. The conversion takes place by forming a homogeneous molten mass in the extruder and forcing it under pressure through an extrusion die orifice that defines the shape of the product's cross section. The formed material, or extrudate, is cooled and drawn away from the die exit at a controlled rate. The extrudate can then be wound on a spool, cut to a specified length, or directed into another in-line process. In this paper a field databased mathematical model is formulated by considering the different important input parameters on which affects the total production output. After evaluation of this model by applying the weighted value technique it is found that the key to successful, efficient extrusion processing is found in taking every parameter that can affect the manufacturing system, and identifying it, controlling it, or monitoring it. The extrusion of pipe is a steady-state process. Anything that happens that alters the steady-state condition will disrupt the steady-state condition and create variation in the product quantity and quality. Keywords: Mathematical modeling, plastic extrusion, PVC pipe.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

1. INTRODUCTION Polyvinyl-Chloride (PVC) is a plastic product which has matchless versatility. It effectively replaces wood, paper and metal in several applications. As such plastic pipes have been progressively replacing conventional pipes like G.I., Cast Iron, Asbestos Cement or Stone-ware for a number of important and uses. Among the various types of plastic pipes which are commonly used for such applications PVC pipes are the most widely used all over the world on account of their most favourable balance of properties. PVC pipes are light in weight, rates for use under pressure, easy to install, low frictional loss, low on maintenance cost, and have low frictional loss. Rigid PVC pipes have wide variety of uses in fields like city/town/rural water supply scheme, spray irrigation, deep tube well schemes and land drainage schemes.PVC pipes are used for a variety of purposes e.g. water supply schemes, spray irrigation, deep tube well schemes and land drainage schemes. PVC slotted and corrugated pipes are ideal systems for drainages of water from land where water logging is inevitable. It is widely used by various utility services now-a-days too. The major consumer of PVC pipes are the Public Health Engineering Department (PHED) and Irrigation Departments. Besides these two, it is used by the Municipal Corporations, Tea estates as well as in N.E. Region. The usage of PVC pipes also depends upon the size of these pipes too. It is manufactured in different sizes having innumerable usage value. 2. PVC PIPE EXTRUSION Extrusion is the basic process for converting thermoplastic resins into continuous lengths of shapes having uniform cross-section. It is indicated for standard profiles such as sheet, film, tubing, rods, and custom profiles of any shape. The overall processing cycle consists of melting the raw material, usually in pellet form, extruding the molten resin through a die that forms the shape of the final part, and then hardening the continuously extruded shape by cooling it as it emerges from the die. The continuous lengths are then reeled or cut to desired length. Extrusion generally involves using a screw [1] [2] that advances the raw material or resin from a feeding hopper through a melting zone. The melted material is forced through an orifice in the die that defines the shape of the end product. The extrusion screw provides frictional heat to help melt the resin, and creates the force to form the desired shape in the die with the pressure needed to obtain the necessary product density. External heat is also applied to the extruder barrel as required. Selection of the feed screw is paramount, since this will dictate whether maximum production rates are achieved, and whether the final product quality is satisfactory. 3. SINGLE SCREW EXTRUDER By far the most common and most versatile extruder in use today is the single-screw extruder [1]. Single-screw extruders are characterized by two dimensions; the bore diameter (D), and the length of the barrel in bore diameters or L/D ratio. The barrel of a single-screw extruder usually is a long, thick walled tube of alloy steel, into which a hard, highly crystalline wear-resistant alloy has been centrifugally cast. Attached to the feed end of the barrel (often as a separate casting) is an opening into the barrel bore for feeding the raw material. It is usually jacketed for room temperature water-cooling to prevent premature
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

melting of polymer. The barrel must be provided with the means to both add and extract heat. Though heaters vary in design, the most common ones are cast aluminum. The heater halves are clamped to the barrel to provide intimate contact between the steel of the barrel and the aluminum of the heater. The heat sink is either air or a liquid coolant. Inside the barrel is a rotating feed screw that picks up the polymer and advances it into and along the barrel. Most of the extrusion screws consist of three zones: Feed zone - 1 to 5 diameters long. Transition zone - to 9 diameters long. Metering or pump zone - to complete the length. The feed zone picks up the resin under the hopper and moves it into the externally heated barrel to begin melting. The transition zone compresses the material, eliminating air pockets and establishing a solid bed of unmelted pellets or powder with melt filling all voids. The conversion of the mechanical energy of the drive to heat occurs to a great extent in this section, an important source of melting energy. The metering or pumping section of the screw generates the pressure needed to force the polymer through the die system. In the process, the rest of the polymer is melted and refined into a homogeneous mass. The gearboxes supplied by extruder manufacturers may be horizontal or vertical, cast iron or welded. They may have helical, herringbone or worm gears. 4. RAW MATERIALS The main raw material required is compounded PVC resin. Presently both PVC & Polyethylene plastics raw materials are indigenously manufactured. Other compounding materials like plasticizers, stabilizers, lubricants and fillers are also manufactured in India. No problem is envisaged for procurement of PVC resin and the other required compounding materials. The raw materials required [2] are as follows: [A] or [X1] PVC resin, [B] or [X2] DOP, [C] or [X3] Stabilizer, [D] or [X4] Processing acids, [E] or [X5] Colourant, [F] or [X6] Filler, [G] or [X7] Other or Impact modifiers. [A] or [X1] PVC resin: PVC uncompounded resin, unlike some other thermoplastics is not suitable for direct processing. To confer the required processing and end instability, it is necessary to mix additives to the PVC resin. Following are some of the additives which are generally used for the manufacture of rigid PVC pipes. [B] or [X2] DOP or Plasticizers: Plasticizers provide PVC with special properties of use similar to those of rubber. This naturally hard material becomes flexible and elastic through plasticizers. At the same time, it retains its shape. The common plasticizer in Use is DINP Diisononyl phthalate, DIDP Disodecyl phthalate, DBP Dibutyl phthalate; BBP benzyl butyl phthalate. Reoplast, Paraplex etc. [C] or [X3] Stabilizers: The use of stabilizers guarantees sufficient heat stability for PVC during processing and protects the end product from change due to heat, UV-light, or oxygen. Especially inorganic and organic salts of the metals calcium, zinc, barium, lead and tin are added to PVC products [2]. The common stabilizers are lead, barium, cadmium, tib, stearate etc. [D] or [X4] Processing Acids or Lubricants: Widely used lubricants are Buty-Stearate, Glycerol Moni - Stearate, Epoxidised Monoester of oleic acid, stearic acid etc. [E] or [X5] Colourant or Pigments: There are three main reasons to use pigments in PVC compounding: to achieve opacity in non-weatherable compounds, for UV protection in
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

weatherable compounds and to achieve a given color. Titanium dioxide is the major pigment used. Other pigments are used in small amounts to achieve the desired color in combination with the titanium dioxide. [F] or [X6] Fillers: Fillers are also used for producing special quality product (e.g. calcined clay is used to improve the electrical properties of cable compounds). [G] or [X7] Other impact modifiers: Certain applications require higher impact strength than PVC would demonstrate normally. Acrylic, chlorinated polyethylene (CPE), methacrylate-butadiene-styrene (MBS), and acrylonitrile-butadiene-styrene (ABS) polymers are normally used to modify impact strength of PVC. These polymers provide a shock absorber when the PVC is heated to a high enough melt temperature 196(C (385(F) to fuse it. At lower melt temperatures, the impact is lower than it would be without impact modification. At this lower melt temperature, the impact modifier acts like a hole or stress concentrator making the impact lower. Using the proper melt temperature will ensure that the full properties of the impact modifier will be realized. Before the extrusion operation PVC resin is to be compounded with plasticizers, stabilizers, lubricants and fillers to improve processibility and improve the endure stability. PVC resin is compounded with other ingredients in a high speed mixer. The compound resin is fed to the double screw extruder where the inserts and die body for the required pipe diameter are fitted. The PVC compounds are then passed through a heated chamber and they get melted under the compression of the screw and temperature of the barrel. The marking on the pipe is done at the time of extrusion. 5. PLANT OUTPUT The production basis for a typical tiny unit would be as under [7]: Working hours/day: 8 (1 shift), Working days in a year: 300, Annual Production capacity: 150 MT PVC Pipes as follows in Table: 1 Sr.No 1 2 Dia of the pipe (mm) 90 110 Production in length (meter) 75000 53571 Weight per running Total production meter (Kgs) (MT) 1000 75 1415 75

6. DATA COLLECTION The annual production (in MT) data was collected from the six industries (PI1, PI2, PI3, PI4, PI5, PI6) located in the area MIDC (Maharashtra Industrial Development Corporation), Jalgaon is as follows in Table: 2
Pipe Industries Plant Output (MT) 80 85 90 95 85 100 A [PVC resin] (MT) 200 180 220 160 210 230 B [DOP] (MT) 10 14 16 9 15 16 C [STABILISER] (MT) 5 4 6 5 6 8 D [PROCESSING ACID] (MT) 4 3 5 5 6 8 E [COLOURANT] (MT) 12 14 10 13 15 16 F [FILLER] (MT) 10 8 6 5 4 4 G [OTHER]

PI1 PI2 PI3 PI4 PI5 PI6

5 4 6 5 4 4

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

7. FORMULATION OF MATHEMATICAL MODEL It is quite clear that these individual factors will have different influence and importance. Thus to evaluate the extent of influence of these factors on production output we consider an exponential model [3] for plant output as follows. Production output (PO) = K x [A]a [B]b [C]c [D]d[E]e [F]f [G]g ----------------- (1) Where, K=constant of proportionality, a, b, c, d, e, f and g are indices of factors A, B,C ,D,E, F and G. The factor indices here shall demonstrate their influence on the respective factors A, B, C, D, E, F and G. The equation (1) can be written in simple first order form by taking the logarithm of both sides of the equation. Thus the equation becomes, Log10 [Production output] = log10 K +a log10 A+ b log10 B+ c log10 C+ d log10 D + e log10 E+ f log10 F + g log10 G The mathematical values of A, B, C, D, E, F and G represents the existing status of the factor in the industry under study. 8. EXAMINATION Questionnaire was prepared for assessing the role of factors and their influence on effectiveness. The questionnaire and weightage design[3] was arrived at consultation with the experts. This exercise led to following weightages. WA = 0.16, WB = 0.14, WC = 0.19, WD = 0.14, WE = 0.13, WF = 0.13, WF = 0.11, Such that WA + WB + WC + ..=1 9. DATA ANALYSIS Data collected is tabulated below in Table: 3
Pipe Industries Plant Output (MT) A or X1 [PVC resin] (MT) 200 180 220 160 210 230 0.16 B or X2 [DOP] (MT) 10 14 16 9 15 16 0.14 C or X3 [STABILISER] (MT) D or X4 [PROCESSING ACID] (MT) 4 3 5 5 6 8 0.14 E or X5 [COLOURANT] (MT) F or X6 [FILLER] (MT) G or X7 [OTHER] (MT)

PI1 PI2 PI3 PI4 PI5 PI6 Weightages

80 85 90 95 85 100

5 4 6 5 6 8 0.19

12 14 10 13 15 16 0.13

10 8 6 5 4 4 0.13

5 4 6 5 4 4 0.11

The weighted values for the data set are given below in Table: 4
Pipe Industries Plant Output (MT) 80 85 90 95 85 100 A or X1 [PVC resin] (MT) 32 28.8 35.5 25.6 33.6 36.8 B or X2 [DOP] (MT) 1.4 1.96 2.24 1.26 2.1 2.24 C or X3 [STABILISER] (MT) 0.95 0.76 1.14 0.95 1.14 1.52 D or X4 [PROCESSING ACID] (MT) 0.56 0.42 0.7 0.7 0.84 1.12 E or X5 [COLOURANT] (MT) 1.56 1.82 1.3 1.69 1.95 2.08 F or X6 [FILLER] (MT) 1.3 1.04 0.78 0.65 0.52 0.52 G or X7 [OTHER] (MT) 0.55 0.44 0.66 0.55 0.44 0.44

PI1 PI2 PI3 PI4 PI5 PI6

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 3, May - June (2013) IAEME

10. OBSERVATIONS FROM WEIGHTED VALUES From the table - 4 of weighted values it is observed that the PVC resin is having highest impact on the production output of the PVC pipes hence it is clear that it is very important input material while DOP and Colourant has moderate impact hence they are important and stabilizer, processing acids, fillers and other material if any, having less or poor impact on total production output of the PVC pipes, hence they are suppose to be less important material as compare to others. 11. CONCLUSION In this paper we have briefly examined the various factors which affect the production output of PVC pipe extrusion process and have categorized them into seven major heads. A field data based mathematical model has been evolved and a data were collected for its further calculation. The data were examined by applying weighted value technique and thus the importance of every factor affecting the production output of PVC pipe extrusion process determined. 12. REFERENCES [1] D.J. Van Zuilichem, W. Stolp, Engineering Aspects of Single- and Twin-screw Extrusion-cooking of Biopolymers, Journal of Food Engineering 2, (1983), p.p 157-l 75 [2] Erdem Selver, Extrusion and Properties of Nanoclay Added Composite Polypropylene Monofilaments, Auburn University Journal, Auburn, Alabama, (2010) [3] Sahu Anil R, Dr.Shrivastava R.L, Dr.Shrivastava R R, Key Factors affecting the effectiveness of technical education An Indian perspective, proceedings of the world congress Engineering, London, Vol II, (2008) [4] PVCplus Kommunikations GmbHAm Hofgarten 1-253113 Bonn, Germany Everything about PVC from manufacturing to recycling (2012) [5] Oxyvinyls, Ingredients Used in Rigid PVC Compounding,technical report 5, (2013) [6] PW Eagle, Technical Bulletin, (2005). [7] Dr. Narai Sailendra, Profiles of SSI Projects, Vol.I, Small Industries Development Bank of India (SIDBI), Lucknow (2009). [8] R. S. Hingole and Dr. V. M. Nandedkar, The Need of Expert System for Forming Analysis of Extrusion Process, International Journal of Mechanical Engineering & Technology (IJMET), Volume 1, Issue 1, 2010, pp. 248 - 252, ISSN Print: 0976 6340, ISSN Online: 0976 6359. [8] Boby K George and Dr. Shouri P.V., Performance Measurement Frame Work Development in Manufacturing Industries by the Application of Theory of Constraints, International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 1, 2012, pp. 14 - 23, ISSN Print: 0976 6340, ISSN Online: 0976 6359.

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