注射成型螺杆的性能评价及优化
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摘要
注射成型是塑料成型最主要的方法之一,而注射螺杆作为注射装置中最关键的零部件,其结构和工作特性对物料的塑化过程有着十分重要的影响,并最终影响到机器的生产效率和产品的质量。如何综合评价注射螺杆性能的好坏,将为注射螺杆的设计提供有利指导,是进一步优化注射螺杆结构的前提。本文在实验的基础上将评价注射螺杆性能标准的几个方面联系起来,结合相关的理论知识建立一套具有实用价值的评价方法。主要的研究内容如下：
(1)对不同结构类型的螺杆进行实验,按照现有的重量重复精度测量标准分别测得不同螺杆在不同工艺条件下加工PP和PS时的重量重复精度值,并根据所获得的实验结果制定出表征螺杆加工制品重量重复性的重量重复精度等级。
(2)采用自行设计的粘度均匀性和温度均匀性的测量方法,分别测得不同螺杆在不同工艺条件下加工PP和PS时的表征粘度均匀性的喷嘴处熔体压力波动及表征温度均匀性的轴向平均温差和径向平均温差,并根据所获得的实验结果制定出表征螺杆塑化质量的熔体粘度均匀性和温度均匀性等级。
(3)利用自行开发的注塑机在线数据采集系统,分别测得不同螺杆头在相同工艺条件下加工PP和PS时的止逆环响应时间及将同一螺杆头安装在不同螺杆上在不同工艺条件下加工PP和PS时的止逆环响应时间,以此来表征螺杆的计量准确性及塑化熔体的质量,并制定出相应的评价等级。
(4)沿机筒方向安装压力传感器,测得不同螺杆在不同工艺条件下加工PP和PS时,塑化过程中计量段部分的沿程压力分布情况,并计算出对应的压力梯度,制定出表征螺杆熔体输送能力的建压能力等级。
(5)对三根变计量段结构参数及两根分离型螺杆进行研究,分析螺杆结构与最终塑化质量之间存在的联系,进而对螺杆的结构进行优化。
Injection molding is one of the most important methods for plastic molding. As key parts of injection device, the structure and operating characteristics of injection screw have important impact on plasticizing process of materials. It will affect the production efficiency of machine and product quality. Comprehensive performance evaluation of injection molding screw will provide beneficial guidance for injection screw design. It is the premise for further optimization of injection molding screw. This subject connected several aspects of performance evaluation standard of injection molding screw basing on the experiment and established evaluation method of some practical value by combining with relevant theoretical knowledge. The main working contents as following:
(1)Experiment on different structure of screws. Repeating weight precision of PP and PS processing by different screws at different process conditions has been measured according to existing repeating weight precision measurement standard. Repeating weight precision grade which characterize weight repeatability of screw machining has been established according to experimental results.
(2)Measurement methods for viscosity and temperature homogeneity has been designed and used. Melt pressure fluctuation at the nozzle which characterize viscosity homogeneity and axial average temperature difference and radial average temperature difference which characterize temperature homogeneity have been measured when PP and PS processing by different screws at different process conditions. Melt viscosity and temperature homogeneity grade which characterize plasticizing quality by screw has been established according to experimental results.
(3)On-line acquisition system for injection molding machine has been developed. Response time of non-return valve has been measured when PP and PS processing by different screw heads and screws at different process conditions. Evaluation grade which characterize metering accuracy and plasticizing quality of screw has been established.
(4)Install pressure sensor along the direction of barrel. Linear pressure distribution at metering section during plasticizing process has been measured when PP and PS processing by different screws at different process conditions. Pressure building ability grade which characterize melt transmission capacity of screw has been established after calculating the pressure gradient.
(5)Study on three different structure parameters of metering section and two separation-type screws. Analyze the relationship between screw structure and final plasticizing quality. Optimize the structure of screw.
(1)对不同结构类型的螺杆进行实验,按照现有的重量重复精度测量标准分别测得不同螺杆在不同工艺条件下加工PP和PS时的重量重复精度值,并根据所获得的实验结果制定出表征螺杆加工制品重量重复性的重量重复精度等级。
(2)采用自行设计的粘度均匀性和温度均匀性的测量方法,分别测得不同螺杆在不同工艺条件下加工PP和PS时的表征粘度均匀性的喷嘴处熔体压力波动及表征温度均匀性的轴向平均温差和径向平均温差,并根据所获得的实验结果制定出表征螺杆塑化质量的熔体粘度均匀性和温度均匀性等级。
(3)利用自行开发的注塑机在线数据采集系统,分别测得不同螺杆头在相同工艺条件下加工PP和PS时的止逆环响应时间及将同一螺杆头安装在不同螺杆上在不同工艺条件下加工PP和PS时的止逆环响应时间,以此来表征螺杆的计量准确性及塑化熔体的质量,并制定出相应的评价等级。
(4)沿机筒方向安装压力传感器,测得不同螺杆在不同工艺条件下加工PP和PS时,塑化过程中计量段部分的沿程压力分布情况,并计算出对应的压力梯度,制定出表征螺杆熔体输送能力的建压能力等级。
(5)对三根变计量段结构参数及两根分离型螺杆进行研究,分析螺杆结构与最终塑化质量之间存在的联系,进而对螺杆的结构进行优化。
Injection molding is one of the most important methods for plastic molding. As key parts of injection device, the structure and operating characteristics of injection screw have important impact on plasticizing process of materials. It will affect the production efficiency of machine and product quality. Comprehensive performance evaluation of injection molding screw will provide beneficial guidance for injection screw design. It is the premise for further optimization of injection molding screw. This subject connected several aspects of performance evaluation standard of injection molding screw basing on the experiment and established evaluation method of some practical value by combining with relevant theoretical knowledge. The main working contents as following:
(1)Experiment on different structure of screws. Repeating weight precision of PP and PS processing by different screws at different process conditions has been measured according to existing repeating weight precision measurement standard. Repeating weight precision grade which characterize weight repeatability of screw machining has been established according to experimental results.
(2)Measurement methods for viscosity and temperature homogeneity has been designed and used. Melt pressure fluctuation at the nozzle which characterize viscosity homogeneity and axial average temperature difference and radial average temperature difference which characterize temperature homogeneity have been measured when PP and PS processing by different screws at different process conditions. Melt viscosity and temperature homogeneity grade which characterize plasticizing quality by screw has been established according to experimental results.
(3)On-line acquisition system for injection molding machine has been developed. Response time of non-return valve has been measured when PP and PS processing by different screw heads and screws at different process conditions. Evaluation grade which characterize metering accuracy and plasticizing quality of screw has been established.
(4)Install pressure sensor along the direction of barrel. Linear pressure distribution at metering section during plasticizing process has been measured when PP and PS processing by different screws at different process conditions. Pressure building ability grade which characterize melt transmission capacity of screw has been established after calculating the pressure gradient.
(5)Study on three different structure parameters of metering section and two separation-type screws. Analyze the relationship between screw structure and final plasticizing quality. Optimize the structure of screw.
引文
[1]王喜顺,颜家华,彭玉成.注射螺杆的熔体输送理论[J].中国塑料,2001.1
[2]北京化工大学,华南理工大学.塑料机械设计[M].北京：中国轻工业出版社,1995.
[3]申长雨,李海梅等,注射成型技术发展概况[J],工程塑料应用,2003.31(3)：53-57
[4]朱复华.螺杆设计及理论基础[M].北京,轻工业出版社,1984.5
[5]张友根.注射螺杆技术进展和设计研究[J].塑胶工业,2007.1
[6]郑启宏.如何选择注塑机螺杆[J].上海塑料,2001.3
[7]冯良为,岑运福.注射螺杆的可靠性设计[J].塑料.2002
[8]王鸳鸯,黄明福.注塑螺杆研究进展[J]广东化工.2007
[9]C.P.J.M.Verbraak and H.E.H.Meijer. Secrew Design in Injection Molding[J]. Polymer Enginefering and Science,1988
[10]Krzysztof Wilczynski.Evaluating Screw Performance in a Single-Screw Extrusion Process [J].POLYM.PLAST.TECHNOL.ENG..1989
[11]Horie M.,Funatsu E.,Ohno E.High Cycle Injection Molding of Phenolic Compound by Newly Designed screw[J].Annual Technical Conference-ANTEC,Conference Proceedings, 1996
[12]金志明,高福荣.新型注塑螺杆性能研究[J].塑料工业,2007.6
[13]戴晓静.注塑机塑化理论的研究及其应用[J].浙江大学.2004
[14]Lia,Hsich F..Molding of flow in a single screw extruder[J].Journal of Food Engineering, 1996
[15]王兴天.注塑技术与注塑机[M].北京,化学工业出版社,2005.8
[16]Donovan R. C.,Thomas D. E.,Leversen L. D.An Experimental Study of Plasticating in a Reciprocating-Screw Injection Molding Machine[J].Polymer and Engineering Science, 1971
[17]0. Amano and S. Utsugi.Temperature measurement of polymer melts in the heating barrel during injection molding[J].Polym Eng Sci,28,1988
[18]N.Sombatsompop,W.Chaiwattanpipat.Temperature profiles of glass fibre-filled polypropylene melts in injection moulding[J].Polymer Testing,1999.6
[19]Verbraak C. P. J. M.,Meijer H. E. H.Screw Design in Injection Molding[J].Polymer and Engineering Science,1989
[20]N. Dontula,P. C. Sukanek,H. Devanathan,and G. A. Campbell.An experimental and theoretical investigation of transient melt temperature during injection moIding[J].Polym Eng Sci,31,1991
[21]A.Osamu and S.Utsugi.ThermocoupIe Measurements of Polymer melts in the heating barrel during injection molding, Part Ⅰ:Temperature distribution along the screw axis in the Reservoir[J].Polym.Eng.Sci.,1988,28(23):1565.
[22]A.Osamu and S.Utsugi.Part Ⅱ:Three-dimensional Temperature Distribution in the Reserbior[J].Polym.Eng.Sci.,1989,29(3):171
[23]Dontula N,Sukanek P C,Devanthan H,et al.An Experimental and Theoretical Investigation of Transient Melt Temperature during Injection Molding[J].Polymer and Engineering Science,1991
[24]C. Liu, L. T. Manzione. Process studies in precision injection molding[J]. Polymer Engineering & Science,1996.9
[25]F. Gao,Z. Jin,X. Chen.A visual barrel system for study of reciprocating screw injection molding[J].Polym Eng Sci,2000
[26]金志明,朱复华,高福荣.注射成型中的熔体温度均匀性研究[J].中国塑料.2003
[27]吴宏武,瞿金平,麻向军.注射成型机使用指南[M].北京,化学工业出版社,2004.3
[28]Chunhua Zhao,Furong GAO.Melt Temperature Profile Prediction for Thermoplastic Injection Molding[J]. Polymer Engineering & Science,1999.9
[29]王喜顺,颜家华,彭玉成.影响注射螺杆塑化能力的因素[J].中国塑料.2001
[30]K. Amellal,B. Elbirli.Performance study of barrier screws in the transition zone[C].SPE Antec,1987
[31]Lipshitz S. D.,Lavie R.,Tadmor Z. A.Melting Model for Reciprocating Screw Injection Molding Machines[J].Polymer and Engineering Science,1974
[32]钟云晴,李木松.一种螺杆塑化能力的计算方法[J].橡塑技术与装备.2003
[33]G.C.Peischle and I.Bruker.Melt Homogeneity in Injection Molding:Application of a Ring-Bar Device[J].Polymer Enginefering and Science,1989
[34]栾军,现代试验设计优化方法[M],上海交通大学出版社,1995
[35]郑少华,姜奉华编著,试验设计与数据处理[M],中国建材工业出版社,2004.3
[36]吴贵生编著,试验设计与数据处理[M],冶金工业出版社,1997.1
[37]Hasan Oktem,Tuncay Erzurumlu, Ibrahim Uzman. Application of Taguchi optimization technique in determining plastic injection molding process parameters for a thin-shell part[J], Materials and Design,2007(28),1271-1278.
[38]张友根.影响注塑制品重量重复精度因素分析研究[J].现代塑料加工应用,2004.6
[39]Christian Maier. Infrared Temperature Measurement of Polymers[J].Polym.Eng.Sci.,1996, 36(11):1502
[40]赵明,周华民.塑料注射成型中注射压力和熔体温度的快速预测[J].中国塑料,2007.9
[41]J. Nanigian. Meet the Ribbon Thermocouple[J].SPE Journal,1971:27,51
[42]A. Galskoy, K. K. Wang. Measuring Melt Temperature:Thermocouple or Pyrometers[J]. Plastics Engineering,1978,34(11):42.
[43]H. Potente and H.S.Paderborn. Melt Temperature Injection Molding Plastication Systems [J].Kunststoffe German Plastics,1990,80(9):40.
[44]Rickey Dubay,Adam C.Bell and Yash P.Gupta.Control of Plastic Melt Temperature:A Multiple Input Multiple Output Model Predictive Approach[M].Polym.Eng.Sci.,1997,37 (9):1550.
[45]T. S. Huxham. Polymer Temperature Measurement in Injection Molding[J].SPE Journal, 1962.889.
[2]北京化工大学,华南理工大学.塑料机械设计[M].北京：中国轻工业出版社,1995.
[3]申长雨,李海梅等,注射成型技术发展概况[J],工程塑料应用,2003.31(3)：53-57
[4]朱复华.螺杆设计及理论基础[M].北京,轻工业出版社,1984.5
[5]张友根.注射螺杆技术进展和设计研究[J].塑胶工业,2007.1
[6]郑启宏.如何选择注塑机螺杆[J].上海塑料,2001.3
[7]冯良为,岑运福.注射螺杆的可靠性设计[J].塑料.2002
[8]王鸳鸯,黄明福.注塑螺杆研究进展[J]广东化工.2007
[9]C.P.J.M.Verbraak and H.E.H.Meijer. Secrew Design in Injection Molding[J]. Polymer Enginefering and Science,1988
[10]Krzysztof Wilczynski.Evaluating Screw Performance in a Single-Screw Extrusion Process [J].POLYM.PLAST.TECHNOL.ENG..1989
[11]Horie M.,Funatsu E.,Ohno E.High Cycle Injection Molding of Phenolic Compound by Newly Designed screw[J].Annual Technical Conference-ANTEC,Conference Proceedings, 1996
[12]金志明,高福荣.新型注塑螺杆性能研究[J].塑料工业,2007.6
[13]戴晓静.注塑机塑化理论的研究及其应用[J].浙江大学.2004
[14]Lia,Hsich F..Molding of flow in a single screw extruder[J].Journal of Food Engineering, 1996
[15]王兴天.注塑技术与注塑机[M].北京,化学工业出版社,2005.8
[16]Donovan R. C.,Thomas D. E.,Leversen L. D.An Experimental Study of Plasticating in a Reciprocating-Screw Injection Molding Machine[J].Polymer and Engineering Science, 1971
[17]0. Amano and S. Utsugi.Temperature measurement of polymer melts in the heating barrel during injection molding[J].Polym Eng Sci,28,1988
[18]N.Sombatsompop,W.Chaiwattanpipat.Temperature profiles of glass fibre-filled polypropylene melts in injection moulding[J].Polymer Testing,1999.6
[19]Verbraak C. P. J. M.,Meijer H. E. H.Screw Design in Injection Molding[J].Polymer and Engineering Science,1989
[20]N. Dontula,P. C. Sukanek,H. Devanathan,and G. A. Campbell.An experimental and theoretical investigation of transient melt temperature during injection moIding[J].Polym Eng Sci,31,1991
[21]A.Osamu and S.Utsugi.ThermocoupIe Measurements of Polymer melts in the heating barrel during injection molding, Part Ⅰ:Temperature distribution along the screw axis in the Reservoir[J].Polym.Eng.Sci.,1988,28(23):1565.
[22]A.Osamu and S.Utsugi.Part Ⅱ:Three-dimensional Temperature Distribution in the Reserbior[J].Polym.Eng.Sci.,1989,29(3):171
[23]Dontula N,Sukanek P C,Devanthan H,et al.An Experimental and Theoretical Investigation of Transient Melt Temperature during Injection Molding[J].Polymer and Engineering Science,1991
[24]C. Liu, L. T. Manzione. Process studies in precision injection molding[J]. Polymer Engineering & Science,1996.9
[25]F. Gao,Z. Jin,X. Chen.A visual barrel system for study of reciprocating screw injection molding[J].Polym Eng Sci,2000
[26]金志明,朱复华,高福荣.注射成型中的熔体温度均匀性研究[J].中国塑料.2003
[27]吴宏武,瞿金平,麻向军.注射成型机使用指南[M].北京,化学工业出版社,2004.3
[28]Chunhua Zhao,Furong GAO.Melt Temperature Profile Prediction for Thermoplastic Injection Molding[J]. Polymer Engineering & Science,1999.9
[29]王喜顺,颜家华,彭玉成.影响注射螺杆塑化能力的因素[J].中国塑料.2001
[30]K. Amellal,B. Elbirli.Performance study of barrier screws in the transition zone[C].SPE Antec,1987
[31]Lipshitz S. D.,Lavie R.,Tadmor Z. A.Melting Model for Reciprocating Screw Injection Molding Machines[J].Polymer and Engineering Science,1974
[32]钟云晴,李木松.一种螺杆塑化能力的计算方法[J].橡塑技术与装备.2003
[33]G.C.Peischle and I.Bruker.Melt Homogeneity in Injection Molding:Application of a Ring-Bar Device[J].Polymer Enginefering and Science,1989
[34]栾军,现代试验设计优化方法[M],上海交通大学出版社,1995
[35]郑少华,姜奉华编著,试验设计与数据处理[M],中国建材工业出版社,2004.3
[36]吴贵生编著,试验设计与数据处理[M],冶金工业出版社,1997.1
[37]Hasan Oktem,Tuncay Erzurumlu, Ibrahim Uzman. Application of Taguchi optimization technique in determining plastic injection molding process parameters for a thin-shell part[J], Materials and Design,2007(28),1271-1278.
[38]张友根.影响注塑制品重量重复精度因素分析研究[J].现代塑料加工应用,2004.6
[39]Christian Maier. Infrared Temperature Measurement of Polymers[J].Polym.Eng.Sci.,1996, 36(11):1502
[40]赵明,周华民.塑料注射成型中注射压力和熔体温度的快速预测[J].中国塑料,2007.9
[41]J. Nanigian. Meet the Ribbon Thermocouple[J].SPE Journal,1971:27,51
[42]A. Galskoy, K. K. Wang. Measuring Melt Temperature:Thermocouple or Pyrometers[J]. Plastics Engineering,1978,34(11):42.
[43]H. Potente and H.S.Paderborn. Melt Temperature Injection Molding Plastication Systems [J].Kunststoffe German Plastics,1990,80(9):40.
[44]Rickey Dubay,Adam C.Bell and Yash P.Gupta.Control of Plastic Melt Temperature:A Multiple Input Multiple Output Model Predictive Approach[M].Polym.Eng.Sci.,1997,37 (9):1550.
[45]T. S. Huxham. Polymer Temperature Measurement in Injection Molding[J].SPE Journal, 1962.889.