This article presents four practical methods for accurately assessing screw wear in extrusion and injection molding machines without disassembly. The methods include melt pressure and position data testing, a pressure drop/backflow evaluation, process reverse deduction through torque and temperature anomalies, and direct borescope inspection. Diagnostic logic linking common symptoms—such as output loss, temperature overshoot, and pressure instability—to specific wear locations is also provided.
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