1. Feed machinery and equipment accessories bulging machine template product introduction
In the field of feed production, the expansion machine is an important equipment, it can make feed raw materials under the action of high temperature, high pressure and high shear force physical and chemical changes, so as to improve the quality and palatability of feed, improve the digestion and absorption rate of feed. As one of the core components of the extruder, the extruder template directly determines the shape, size, density and quality of the extruder feed.
2. Structural characteristics
Template body
The main body of the bulking machine template is usually a round or rectangular metal plate with a certain thickness and area. Its thickness depends on the model of the extruder, the production capacity and the pressure it is subjected to, generally between 10-50 mm. The material of the template body needs to have high strength and heat resistance to withstand the impact and extrusion of high temperature and high pressure materials during the expansion process. On the main body of the template, a large number of die holes are distributed, and these die holes are channels for extruding extruded materials to form feed particles of a specific shape.
Die design
The shape, size, depth and arrangement of the die holes are the key elements in the design of the extruder template. The common mold hole shapes are round, square, hexagonal, ring, etc. Different shapes will make the expanded feed show different appearances. For example, the feed particles produced by the circular mold holes are cylindrical, which is suitable for most livestock and aquatic animals to eat; The square die hole can produce a square block of feed, which is used more in some pet feed or special feed formulas. The size of the die hole determines the diameter or side length of the feed particles, which can range from a few millimeters to tens of millimeters, and can be adjusted according to the feeding needs and growth stages of different animals. The depth of the die hole is related to the length of the feed particles, and the deeper die hole can produce longer particles, but it will also increase the residence time and extrusion resistance of the material in the template. The arrangement of die holes on the template usually has concentric circle arrangement, spiral arrangement, matrix arrangement, etc. A reasonable arrangement can ensure that the material is evenly distributed in the extrusion process, improve the overall strength and wear resistance of the template, and reduce the damage caused by excessive local pressure.
Inlet and outlet design
The expansion machine template is provided with a feed port, and the position and shape of the feed port need to match the screw structure of the expansion machine so that the material can enter the template smoothly. The feed port is generally located in the center of the template or near the center, and its shape may be round, square or other special shapes, and the size depends on the flow rate of the material and the diameter of the screw. The discharge port is the die hole. On the other side of the template, the material is extruded through the die hole to form expanded feed particles. In order to facilitate the extrusion of materials and the molding of particles, there is usually a certain transition corner or cone design around the discharge port to reduce the resistance and shear force of the material at the exit and prevent the fracture or deformation of particles.
Connecting and fixing the structure
The bulking machine template needs to be reliably connected and fixed with the bulking machine body or other components. The edge or back of the template is usually provided with a connecting structure such as mounting holes, positioning pin holes or card slots. The mounting holes are used to fasten the template to the bulking machine body by bolts, and the positioning pin holes ensure the precise installation position of the template to prevent rotation or displacement during operation. The card slot structure can be connected with the specific parts of the expansion machine, which is convenient for the installation and disassembly of the template. The design of these connection structures needs to ensure that the template can maintain a stable connection state under high temperature, high pressure and strong vibration working environment, without loosening, leakage and other problems.
3. Material characteristics
High quality alloy steel
Many extruder templates are made of high quality alloy steel, such as 40Cr, 42CrMo, etc. These alloy steels have high strength, toughness and heat resistance. After the tempering treatment, the hardness of 40Cr alloy steel can reach HRC28-32, which can meet the requirements of strength and heat resistance of the general expansion machine die plate. In the expansion process, it can withstand the extrusion and friction of the material, and is not easy to deformation or damage. 42CrMo alloy steel contains molybdenum element, further improve the hardenability and strength of the material, after tempering and surface quenching treatment, the surface hardness can be increased to HRC50-55, in large, heavy duty or high temperature and high pressure environment more harsh extruder performance. For example, in some puffing machines that produce aquatic feed or pet feed, because the feed formula may contain more protein, fat and other components, higher pressure and temperature will be generated during the puffing process, 42CrMo alloy steel templates can better cope with this situation to ensure the service life of the templates and the molding quality of feed particles.
Stainless steel
Stainless steel extruder template is widely used in the occasions with high requirements for feed hygiene, such as the production of food grade feed or some special aquatic feed. For example, 304 stainless steel has good corrosion resistance and oxidation resistance, which can prevent the water, acid and alkali components in the feed and the erosion of microorganisms on the template, ensuring the quality and safety of feed particles. The stainless steel template also has a good surface finish, which is conducive to the extrusion of materials and the molding of particles, and reduces the adhesion and damage of the particle surface. In addition, some higher grades of stainless steel, such as 316 stainless steel, have greater corrosion resistance and are suitable for extruder templates that contain more corrosive additives or work in harsher environments.
Special alloy material
For some special feed raw materials or production processes, it may be necessary to use special alloy materials to make expansion machine templates. For example, when producing feed containing high fiber or high hardness additives, alloy materials with higher hardness and wear resistance are used, such as tungsten carbide alloy or cobalt-based alloy. These special alloy materials are better able to cope with complex feedstock characteristics, ensuring that the template can maintain good performance under harsh working conditions and produce feed pellets that meet the requirements. At the same time, some new alloy materials may also have self-lubricating or special heat conduction properties, which can further optimize the bulking process and improve production efficiency and feed quality.
4. Manufacturing process
Forged blank
The blank of the expansion machine template is usually prepared by forging process. Forging can refine the grain of the metal material and make the organization more dense, thereby improving the strength and toughness of the material, and eliminating the internal defects caused by the metal in the smelting process. The blank after forging needs to be normalized or annealed to eliminate the forging stress, improve the cutting performance of the material, and lay a good foundation for the subsequent machining process. For example, for 40Cr alloy steel template blank, normalization treatment after forging can homogenize the organization, moderate hardness, easy to perform turning, drilling and other processing operations.
machining
Machining is the key link of the extruder template manufacturing, including turning, milling, drilling, boring, grinding and other processes. First, the outer circle, inner hole and end face of the blank are processed to the design size through turning processing, and the installation hole, positioning pin hole and other features are processed. In the turning process, it is necessary to strictly control the accuracy and surface roughness of each size to ensure the accurate fit of the template with other parts of the extruder. Then the milling process is used to process some special shapes or structures on the surface of the template, such as the shape of the feed port, the inlet chamfer of the die hole, etc. For the processing of die holes, usually using the drilling and boring process, the initial hole is drilled first, and then the hole is refined through the boring process to ensure the dimensional accuracy, cylindricity and surface roughness of the die holes. In some demanding template manufacturing, special machining methods such as EDM or laser machining may also be used to process the die holes to obtain higher accuracy and special die hole shapes. Finally, the key mating surfaces of the formwork, such as the outer circle and the end face, can be finely ground using the grinding process to further improve the surface accuracy and finish, ensuring stability and sealing after installation. In the machining process, it is necessary to use high-precision machine tool equipment and tools, and strictly control the processing parameters of each process to ensure the manufacturing quality of the extruder template.
5. Performance advantage
High precision forming
The mold holes of the extruder template are precisely machined to ensure the shape and size accuracy of feed particles. Whether round, square or other shaped die holes, feed particles can be extruded with a high degree of consistency to meet the strict requirements of different animal feed particle specifications. For example, in the production of pet feed, the precise particle shape and size have an important impact on the feeding habits and digestion and absorption of pets, and the high-precision molding capacity of the extruder template can ensure that the pet feed particles produced meet the market demand and improve the competitiveness of the product.
High wear resistance
Because in the process of expansion, the die holes of the template need to constantly contact with high temperature and high pressure feed materials and withstand huge friction, high wear resistance is an important performance advantage. Using high-quality alloy steel, stainless steel or special alloy materials, combined with appropriate heat treatment and surface treatment process, the template can effectively resist wear and reduce the deformation and damage of the die hole. In the course of long-term use, the highly wear-resistant formwork can significantly reduce equipment maintenance costs and downtime, and improve production efficiency. For example, in a large feed expansion plant, a set of high-quality templates can work for thousands of hours without frequent replacement, ensuring stable operation of the production line.
Good heat resistance
During the operation of the extruder, the material will undergo high temperature treatment, and the template needs to withstand the test of high temperature environment. Its high-quality material and reasonable structural design make the template have good heat resistance, can maintain stable mechanical properties at high temperatures, without softening, deformation or damage. This is essential to ensure the normal expansion process and the quality of feed particles, for example, in the production of aquatic feed, due to the need for a higher swelling temperature to ensure the stability of feed in water, the good heat resistance of the template is enough to ensure the continuous production of feed particles under high temperature conditions.
6. FAQ
Q: What is the main material of the extruder template?
A: The extruder formwork is usually made of high-strength steel or alloy steel to ensure that it has sufficient strength and wear resistance. These materials can withstand high loads and long periods of use.
Q: What are the surface treatment processes of the extruder template?
A: The common surface treatment process of the bulking machine template includes quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: How to ensure the transmission efficiency of the expansion machine template?
A: In order to ensure the transmission efficiency of the expansion machine template, the coordination accuracy between the shaft and the template should be ensured, the lubrication system should be regularly checked and maintained, and the lubricating oil should be kept clean and appropriate.
Q: What problems may occur in the use of the extruder template?
A: The extruder template may have problems such as wear, fracture, deformation or poor fit during use. These problems are usually caused by overload, inadequate lubrication, or material defects.
Q: What are the special requirements of extruder templates in different application scenarios?
Answer: In different application scenarios, the extruder template may have different special requirements. For example, extruder templates used in high temperature environments need to have high temperature resistance; For use in corrosive environments, corrosion-resistant materials are required.
Q: What are the heat treatment processes of the bulking machine template?
A: The heat treatment process of the bulking machine template includes quenching, tempering and normalizing. These processes can improve the mechanical properties of the material, increase its hardness and wear resistance, and thus extend the service life of the expansion machine template.
