1, High die loss and cost
During the extrusion molding process, the mold is a key component that determines the shape and size of the product. However, the mold will bear enormous pressure and friction during the extrusion process, resulting in wear and tear of the mold. The loss of molds not only affects the quality and accuracy of products, but also increases the cost of mold replacement and maintenance. In addition, the manufacturing and processing of high-quality molds also require a significant investment of funds and technology, further increasing production costs.
2, Uneven deformation of the inner and outer layers, as well as the front and rear ends of the material
During the extrusion molding process, the flow of materials inside the mold is uneven, especially in the absence of lubrication or poor lubrication. This uneven flow can lead to inconsistent deformation of the inner and outer layers, as well as the front and rear ends of the material, thereby affecting the microstructure and mechanical properties of the product. For example, there may be significant differences in the tissue properties of the surface and center, as well as the head and tail of extruded products, resulting in uneven strength, hardness, toughness, and other properties of the product.
3, Relatively low production efficiency
Although extrusion molding has the ability for continuous production, its production efficiency is still relatively low compared to other molding processes such as injection molding or blow molding. This is mainly because the extrusion molding process requires continuous replacement of molds and adjustment of process parameters to adapt to the production of products with different shapes and sizes. In addition, the automation level of extrusion molding equipment is relatively low, requiring more manual operation and monitoring, further reducing production efficiency.
4, Product accuracy and surface quality are limited
The accuracy and surface quality of extruded products are influenced by various factors, such as the precision of the mold, the fluidity of the material, the extrusion speed, and temperature. Due to uneven material flow and mold wear during the extrusion process, there may be some deviation in the size and shape accuracy of the product. Meanwhile, the surface quality of extruded products may also be affected by factors such as mold surface quality, material adhesion, and lubrication effect, resulting in defects such as scratches, pits, or bubbles.
5, High material requirements
Extrusion molding requires high plasticity, flowability, and thermal stability of materials. The unsuitability of materials may lead to problems such as blockage, fracture, or deformation during the extrusion process, affecting the quality and production efficiency of the product. In addition, there are differences in the extrusion process parameters of different materials, which need to be adjusted and optimized according to the characteristics of the materials, increasing the complexity and cost of the production process.
6, Poor production environment and safety hazards
During the extrusion molding process, due to the high temperature and pressure state of the material, as well as the friction and vibration of the mold and equipment, a large amount of pollutants such as heat, noise, and dust will be generated. These pollutants not only affect the hygiene and comfort of the production environment, but may also pose potential threats to the health and safety of workers. At the same time, the high temperature and high pressure conditions of extrusion molding equipment also increase safety hazards during operation, and effective safety and protective measures need to be taken to ensure the safety of workers.
7, Difficult to produce complex shapes and precision products
Although extrusion molding can produce products in various shapes and sizes, there are certain difficulties in producing complex shapes and precision products. This is mainly because the flow of materials during the extrusion molding process is limited by the shape and size of the mold, making it difficult to achieve the production of complex shapes and precision structures. In addition, the size and shape accuracy of extruded products are also affected by mold accuracy and extrusion process parameters, making it difficult to meet the requirements of high-precision and high-quality products.
