import pandas as pd
import numpy as np
import altair as alt
from extrucal.extrusion import throughput_cal
[docs]def sheet_cal(width, thickness, l_speed, s_density):
"""
Calculates the required throughput for sheets given the width,
thickness, line speed, and solid polymer density
Parameters
----------
width : int or float
Sheet width [mm]
thickness : int or float
Sheet thickness [mm]
l_speed : int or float
Line speed [mpm]
s_density : int or float
Solid density of polymeric material [kg/m^3]
Returns
-------
throughput : float
required exturion throughput [kg/hr]
Examples
--------
>>> sheet_cal(width=1000, thickness=1, l_speed = 1, s_density=1000)
"""
# Test input type
if not isinstance(width, int):
if not isinstance(width, float):
raise TypeError("'width' should be either integer or float")
if not isinstance(thickness, int):
if not isinstance(thickness, float):
raise TypeError("'thickness' should be either integer or float")
if not isinstance(l_speed, int):
if not isinstance(l_speed, float):
raise TypeError("'l_speed' should be either integer or float")
if not isinstance(s_density, int):
if not isinstance(s_density, float):
raise TypeError("'s_density' should be either integer or float")
# Test input value
if s_density < 300:
raise ValueError("This is not solid density for polymers. Too low!!")
if s_density > 3000:
raise ValueError("This is not solid density for polymers. Too high!!")
# Calculate basic variables
cross_area = width * thickness / 1000000
req_throughput = l_speed * cross_area * 60 * s_density
return round(req_throughput, 3)
[docs]def sheet_table(
width, thickness, s_density, density_ratio=0.85, min_l_speed=1,
max_l_speed=10, delta_l_speed=1, min_size=20, max_size=100, delta_size=20,
depth_percent=0.05
):
"""
Generate a table containing the required screw RPM with respect to
line speed and extruder size
Parameters
----------
width : int or float
Sheet width [mm]
thickness : int or float
Sheet thickness [mm]
s_density : int or float
Solid density of polymeric material [kg/m^3]
density_ratio : int or float
Ratio b/w solid and melt density
min_l_speed : int or float
Minimum line speed for calculation [mm]
Default value is 1 (1mpm)
max_l_speed : int or float
Maximum line speed for calculation [mpm]
Default value is 10 (10mpm)
delta_l_speed : int or float
Amount of increment in line speed for calculation [mpm]
Default value is 1 (1mpm)
min_size : int or float
Minimum extruder size for calculation [mm]
Default value is 20 (20mm)
max_size : int or float
Maximum extruder size for calculation [mm]
Default value is 100 (100mm)
delta_size : int or float
Amount of increment in extruder size for calculation [mm]
Default value is 20 (20mm)
depth_percent : int or float
Percentage of the depth of metering channel compared to extruder size
Default value is 0.05
Returns
-------
table : pandas.DataFrame
dataframe containing the required screw RPM as a function of line speed and extruder size
Examples
--------
>>> sheet_table(width=1000, thickness=1, s_density=1000)
"""
# Test input type
if not isinstance(width, int):
if not isinstance(width, float):
raise TypeError("'width' should be either integer or float")
if not isinstance(thickness, int):
if not isinstance(thickness, float):
raise TypeError("'thickness' should be either integer or float")
if not isinstance(s_density, int):
if not isinstance(s_density, float):
raise TypeError("'s_density' should be either integer or float")
if not isinstance(density_ratio, int):
if not isinstance(density_ratio, float):
raise TypeError("'density_ratio' should be either integer or float")
if not isinstance(min_l_speed, int):
if not isinstance(min_l_speed, float):
raise TypeError("'min_l_speed' should be either integer or float")
if not isinstance(max_l_speed, int):
if not isinstance(max_l_speed, float):
raise TypeError("'max_l_speed' should be either integer or float")
if not isinstance(delta_l_speed, int):
if not isinstance(delta_l_speed, float):
raise TypeError("'delta_l_speed' should be either integer or float")
if not isinstance(min_size, int):
if not isinstance(min_size, float):
raise TypeError("'min_size' should be either integer or float")
if not isinstance(max_size, int):
if not isinstance(max_size, float):
raise TypeError("'max_size' should be either integer or float")
if not isinstance(delta_size, int):
if not isinstance(delta_size, float):
raise TypeError("'delta_size' should be either integer or float")
if not isinstance(depth_percent, int):
if not isinstance(depth_percent, float):
raise TypeError("'depth_percent' should be either integer or float")
# Test input value
if s_density < 300:
raise ValueError("This is not solid density for polymers. Too low!!")
if s_density > 3000:
raise ValueError("This is not solid density for polymers. Too high!!")
if density_ratio > 1:
raise ValueError("Melt density can't be greater than solid density")
if density_ratio < 0.5:
raise ValueError("Melt density is too low (<50% of solid density)")
if delta_l_speed > max_l_speed-min_l_speed:
raise ValueError("'delta_l_speed' can not be greater than 'max_l_speed - min_l_speed'")
if delta_size > max_size-min_size:
raise ValueError("'delta_size' can not be greater than 'max_size - min_size'")
if depth_percent < 0.01:
raise ValueError("Channel depth is too shallow(<1% of screw size) to be used for extrusion screw")
if depth_percent > 0.3:
raise ValueError("Channel depth is too deep(>30% of screw size) to be used for extrusion screw")
# Generates table
table = dict()
rpm_list = list()
l_speed = [round(i, 2) for i in np.arange(min_l_speed, max_l_speed+0.001, delta_l_speed)]
size = [j for j in np.arange(min_size, max_size+0.1, delta_size)]
size_title = [f"{k}mm Ext" for k in np.arange(min_size, max_size+0.1, delta_size)]
for l in l_speed:
for s in size:
rpm_list.append(
round(
(sheet_cal(width, thickness, l, s_density)/
throughput_cal(s, s*depth_percent, s_density*density_ratio)),
2))
table[f"{l}mpm"] = rpm_list
rpm_list = []
table_df = pd.DataFrame(table, index=size_title)
return table_df
[docs]def sheet_plot(
width, thickness, s_density, density_ratio=0.85, min_l_speed=1,
max_l_speed=10, delta_l_speed=1, min_size=20, max_size=100, delta_size=1,
depth_percent=0.05
):
"""
Generate a plot containing the required screw RPM with respect to
line speed and extruder size
Parameters
----------
width : int or float
Sheet width [mm]
thickness : int or float
Sheet thickness [mm]
s_density : int or float
Solid density of polymeric material [kg/m^3]
density_ratio : int or float
Ratio b/w solid and melt density
min_l_speed : int or float
Minimum line speed for calculation [mm]
Default value is 0 (0mpm)
max_l_speed : int or float
Maximum line speed for calculation [mpm]
Default value is 10 (10mpm)
delta_l_speed : int or float
Amount of increment in line speed for calculation [mpm]
Default value is 1 (1mpm)
min_size : int or float
Minimum extruder size for calculation [mm]
Default value is 20 (20mm)
max_size : int or float
Maximum extruder size for calculation [mm]
Default value is 100 (100mm)
delta_size : int or float
Amount of increment in extruder size for calculation [mm]
Default value is 5 (5mm)
depth_percent : int or float
Percentage of the depth of metering channel compared to extruder size
Default value is 0.05
Returns
-------
plot : altair.Chart object
a line chart showing the required screw RPM as a function of line speed and extruder size
Examples
--------
>>> sheet_plot(width=1000, thickness=1, s_density=1000)
"""
# Test input type
if not isinstance(width, int):
if not isinstance(width, float):
raise TypeError("'width' should be either integer or float")
if not isinstance(thickness, int):
if not isinstance(thickness, float):
raise TypeError("'thickness' should be either integer or float")
if not isinstance(s_density, int):
if not isinstance(s_density, float):
raise TypeError("'s_density' should be either integer or float")
if not isinstance(density_ratio, int):
if not isinstance(density_ratio, float):
raise TypeError("'density_ratio' should be either integer or float")
if not isinstance(min_l_speed, int):
if not isinstance(min_l_speed, float):
raise TypeError("'min_l_speed' should be either integer or float")
if not isinstance(max_l_speed, int):
if not isinstance(max_l_speed, float):
raise TypeError("'max_l_speed' should be either integer or float")
if not isinstance(delta_l_speed, int):
if not isinstance(delta_l_speed, float):
raise TypeError("'delta_l_speed' should be either integer or float")
if not isinstance(min_size, int):
if not isinstance(min_size, float):
raise TypeError("'min_size' should be either integer or float")
if not isinstance(max_size, int):
if not isinstance(max_size, float):
raise TypeError("'max_size' should be either integer or float")
if not isinstance(delta_size, int):
if not isinstance(delta_size, float):
raise TypeError("'delta_size' should be either integer or float")
if not isinstance(depth_percent, int):
if not isinstance(depth_percent, float):
raise TypeError("'depth_percent' should be either integer or float")
# Test input value
if s_density < 300:
raise ValueError("This is not solid density for polymers. Too low!!")
if s_density > 3000:
raise ValueError("This is not solid density for polymers. Too high!!")
if density_ratio > 1:
raise ValueError("Melt density can't be greater than solid density")
if density_ratio < 0.5:
raise ValueError("Melt density is too low (<50% of solid density)")
if delta_l_speed > max_l_speed-min_l_speed:
raise ValueError("'delta_l_speed' can not be greater than 'max_l_speed - min_l_speed'")
if delta_size > max_size-min_size:
raise ValueError("'delta_size' can not be greater than 'max_size - min_size'")
if depth_percent < 0.01:
raise ValueError("Channel depth is too shallow(<1% of screw size) to be used for extrusion screw")
if depth_percent > 0.3:
raise ValueError("Channel depth is too deep(>30% of screw size) to be used for extrusion screw")
# Generate table for plot
table = dict()
rpm_list = list()
l_speed = [round(i, 2) for i in np.arange(min_l_speed, max_l_speed+0.001, delta_l_speed)]
size = [j for j in np.arange(min_size, max_size+0.1, delta_size)]
for l in l_speed:
for s in size:
rpm_list.append(sheet_cal(width, thickness, l, s_density)/
throughput_cal(s, s*depth_percent, s_density*density_ratio))
table[l] = rpm_list
rpm_list = []
table_df = pd.DataFrame(table, index=size)
table_for_plot = table_df.reset_index()
table_for_plot = table_for_plot.rename(columns={"index": "size"})
table_for_plot = table_for_plot.melt(id_vars="size", var_name="speed", value_name="rpm")
table_for_plot["speed"] = table_for_plot["speed"].astype('category')
# Generate plot
plot = alt.Chart(table_for_plot, title='Screw RPM vs Extruder Size & Line Speed').mark_line().encode(
alt.X("size", title="Extruder Size", scale=alt.Scale(domain=(min_size, max_size))),
alt.Y("rpm", title="Screw RPM"),
alt.Color(
"speed", title="Line Speed [mpm]",
sort=alt.EncodingSortField('rpm', op='mean', order='descending')
),
tooltip=["size", "speed", "rpm"]
).configure_axis(
labelFontSize=14, titleFontSize=16
).configure_legend(
labelFontSize=16, titleFontSize=14
).configure_title(
fontSize=18
)
return plot