1 (edited by AndersE 2018-02-16 22:38:21)

Topic: Questions about extrusion variations ,any expert?

I built a filament extruder couple of years ago, i snipped ideas and stuff from the net and
obviously some from filastruder, but i have never got any good diameters. And YES i predry all material.

It extrudes both pla and abs 3mm (2.8) ok, good quality and so. Printable but:

I get diameter variances that goes in waves. and i *think* waves superimposed on the big waves.

The upper wave show what it looks if i measures over aproximately 50cm to 100cm depending on speed.
But if i measure over a longer period ( couple of meters) i start to see a wave superimposed over the 50-100cm.

the 50-100cm variation is about 0.05mm and the second is about 0.1mm, but at certain moments
the waves adds onto each other so the variation sometimes is 0.15-0.2mm.

So for like 5m i get ok diameter, then the next 5m is way to big variation, the next 5m is then again ok.

At first i thought it was because i had a winder that start, stop at intervals. So i made a winder that runs continusly
at fixed speed, and it was then i got a visual of it.  The shadow on the sensor slowly went up, then down and after a couple of oscillations it got bigger and bigger then suddenly smaller and smaller until it was back at the small up/downs.

So. Is my problem with the auger? The nozzle? Too small meltzone? Too small/big gap between augerend and nozzle?
It must have something with pressure buildups to do i think.
The nozzle has meltfilter, then a breaker (just a plug with about 10holes, the plug is coned inwards closest to nozzle, the nozzle is flat. maybe i should have a nozzle that is coned on the inside?

The motor is a BIG 230v motor (2hp?) with 34rpm gearbox into a 16mm auger. Motor is run from a Variable Frequency Drive.
The VFD makes sure the motor runs the same speed even at load.
I have two melt-zones aprox 10cm apart. 2 PID controllers both pidtuned. First melt-zone a little cooler then the second.
Vertical mounted with loop to the floor then up to winder.

I have tried speeds (augerspeed) from 6rpm (1kg in 8hours) up to 25rpm (1 kg in 3 hours), and i have tried different temperatures.

I really hope you all understand what i mean (english is NOT my first language).

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2

Re: Questions about extrusion variations ,any expert?

I  have ordered two other pid controllers that i hope are better holding temps after pidtuning. REX -C100 seems to be bad.
Hope it is that.

Nobody have any input?

3

Re: Questions about extrusion variations ,any expert?

Looks like you have feedback loops bouncing off each other. Try disabling one PID to see what happens or set the parameters inside the least critical PID to an extreme.

Tevo Black Widow
MonoPrice Mini Delta
TonXY X5S-400, 2 each
Filastruder and Filawinder on order