Efficient Blank Production: FKM Rubber Cords through Modern Extrusion

Blank manufacturing is a fundamental process that underpins the production of high-quality and high-performance end products. It significantly enhances the efficiency, flexibility, and innovative capacity of a company, making it an indispensable component of modern industrial production.

A particularly important area of blank manufacturing is the production of rubber cords, especially from FKM (fluoroelastomer). These cords have a wide range of applications and offer special advantages due to their excellent chemical resistance and high temperature stability. In this article, we examine the extrusion processes for the production of FKM rubber cords and their benefits for industrial production.
 

A key technology in Blank Manufacturing

Rubber cords are produced using extrusion technology and have a wide range of industrial applications, such as seals, O-rings, or flexible connections. An outstanding material for such applications is FKM (fluoroelastomer), also known by the trade names Viton™, FPM (Fluorinated Propylene Monomer), FFKM (Perfluoroelastomer), FEPM (Tetrafluoroethylene Propylene Rubber), and FVQM (Fluorosilicone Rubber).
 

Advantages of FKM in Blank Manufacturing
 

1. Chemical Resistance: FKM exhibits excellent resistance to mineral oils, fats, fuels, and hydraulic fluids. This makes it an ideal material for applications requiring high resistance to aggressive substances.
    
2. Temperature Range: FKM can be used in a wide temperature range from -20°C to 500°C. This high-temperature stability allows its use in extreme environments, increasing the versatility of the manufactured blanks.
    
3. Hardness Range: The hardness range of FKM can vary between 60 and 85 Shore A. This allows the mechanical properties of the blanks to be adjusted according to application needs.

The Extrusion Process for FKM Rubber Cords

Extrusion is a continuous process in which the elastomer is pressed through a specially shaped die to obtain the desired shape. In the production of FKM rubber cords, smaller extruders are typically used because the material is expensive and must be processed efficiently—usually a 32- or 45-mm extruder.

 

Process Steps of FKM Extrusion for Blank Manufacturing:

1. Material Preparation: The FKM material is prepared and homogenized before the extrusion process. This ensures that the material properties are evenly distributed and the extrusion quality remains consistent.
    
2. Extrusion: The prepared FKM is pushed through the extruder, which is equipped with a die set to the desired shape and size of the cords. The high precision of the die allows for the production of cords with tight tolerances.
    
3. Cooling and Cutting: After extrusion, the cords are cooled and cut to the required length. Cooling can be done by air or water, depending on the specific requirements of the material and application.
    
    
    

Requirements for the Extrusion Process

To ensure an efficient extrusion process, the following requirements should be met:
 

1. Small compound batch quantities: The extrusion process should be flexible enough to efficiently process small amounts of compound material.
    
2. Easy to clean extruder: The extruder must be easy to clean in order to minimise material residues and maintain the quality of the compound. The material in the extruder should be recoverable.
    
3. Avoidance of contamination: It is essential that no contaminants enter the mixture to ensure the purity and performance of the rubber cords.
    
4. Temperature control: Precise temperature control of the machine is necessary to control the surface quality of the preforms.
    
5. Good cross-section and weight/metre tolerance: The extrusion process must ensure very good tolerances in terms of cross-section and weight per metre in order to produce consistent, high-quality products.
   
   
    

Advantages of FKM Extrusion for Rubber Cords

• Precision and consistency: Extrusion enables the production of cords with very tight tolerances, resulting in high product quality.
   
• Efficiency: The continuous process of extrusion ensures a high production speed and reduces material waste.
   
• Flexibility: The ability to use different die moulds allows the production of cords in different sizes and profiles.

Extrusion Technology for Blank Manufacturing by rubicon

rubicon offers machines and systems for the production of blanks that are customised to your specific requirements. Extruders, extrusion tools, semi-automatic strip feeders and cutting machines, cooling devices, haul-off belts and winders are used specifically for the production of blanks and preforms. 

Our modern extruders are capable of producing a variety of shapes and sizes with high precision and efficiency. The integration of laser measurement systems and automated cutting units allows for the production of products with tight tolerances, leading to improved quality and cost savings.

 

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