混凝土振动搅拌机理和工业应用研究
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摘要
目前，原材料级配、性能及新拌混凝土成型等是国内外有关混凝土研究的焦点，而搅拌过程却往往被忽视和研究不够。究其原因，主要是因为搅拌过程涉及多学科交叉领域，如搅拌设备、施工材料和生产工艺等，认知起来比较困难，研究过程中易相互脱节。所以，相关研究至今仍停留在宏观尺度上。致使混凝土微观匀质性较差，界面粘结强度较低；搅拌工作装置的线速度较低，搅拌时间长；搅拌过程存在速度梯度和搅拌低效区等现象长期得不到根本解决。本文提出利用振动与普通静力搅拌相结合的新方法，利用动力学原理设计振动器，置于圆形拌筒的中心，振动器埋在混合料中，振动能量直接被混合料吸收。在两种方式共同作用下，混凝土微观结构和力学性能得以改善，搅拌设备综合性能得以提升。
论文首先分析了新拌混凝土结构-流变特性，为确定振动搅拌设备工作机构的几何、运动参数提供理论依据，指出各参数的选取需以保证搅拌筒内混合料结构的完全破坏为目标；进一步分析了混凝土搅拌过程及目前普遍采用的普通静力搅拌所存在的不足。
分六大方面，论文重点对混凝土振动搅拌方式改善搅拌过程及混凝土性能的机理进行了详细阐述，包括：振动搅拌对混凝土结构-流变特性的影响机理；振动搅拌对新拌混凝土中水泥团粒的破坏机理；振动搅拌对新拌混凝土中粗骨料表面的净化及其粘结强度的增强机理；振动搅拌对新拌混凝土中气相生成物的影响机理；振动搅拌对搅拌过程—低效区的改善机理；振动搅拌对多材料的适应性机理。理论分析认为，振动搅拌可综合提高搅拌设备及混凝土各项性能。
在理论分析的基础上，设计了两台试验样机：振动与静力搅拌相结合，但振动与搅拌工作装置分离的立轴式振动搅拌机，以及振动与静力搅拌工作装置相结合的一体式双卧轴振动搅拌机；进行了振动搅拌对普通混凝土、RCC、SFRC、CA砂浆等材料的适应性试验研究。初步得出了振动搅拌各参数的合理取值及匹配关系，为振动搅拌设备的工业化提供依据。试验结果表明：振动搅拌对多材料具有较好的适应性，各项性能指标均优于普通静力搅拌；立轴振动搅拌更适宜于骨料颗粒普遍较小的CA砂浆等材料的搅拌，双卧轴振动搅拌更适宜于较大粒径骨料的混凝土搅拌。
在理论分析和大量试验研究的基础上，针对现行搅拌设备评定指标体系的不合理性进行了试验证明和分析，并对修改现行搅拌设备评定指标提出了若干建议，给出在不同场合下需要增加的检验指标，旨在完善现行搅拌设备评定指标体系。
将理论及试验研究成果与工业实际相结合，试制了1m3双卧轴振动搅拌工业样机，并进行了工业化研究。研究表明：工业样机工作过程稳定可靠，各项指标满足国标要求，能耗较低，搅拌时间为45s；其他条件相同的情况下，工业样机生产的混凝土比普通静力搅拌机生产的混凝土强度提高15%以上，且新拌混凝土匀质性更好；工业样机在减少水泥15%时，混凝土性能仍满足设计要求，节约水泥效果明显。
本课题研究受到国家自然科学基金项目“混凝土振动拌和机理研究”（50678026）、陕西省重大科技创新专项资金项目“高效混凝土搅拌机的工业化研究”（2008ZKC01-16）资助。
At the present time, the focus of concrete research at home and abroad is materialgraduation, material performance and fresh concrete molding, but not the mixing process.The reason is that the mixing process involves mixing equipment, mixing materials andconstruction technology which belong to different disciplines, and easily divorced from eachother during the research process, so the study of mixing process is still at the macroscopicscale up to now, and this results in some problems, such as poor microstructure uniformity,low interfacial bond strength, low mixing speed, long mixing time, mixing velocitygradient and mixing inefficient zone and so on. The author in this paper presented a newvibratory mixing method with the combination of forced mixing, placing a vibration exciterthat designed by dynamic balance principle in the middle of mixing tube, and thevibrational energy from the exciter will be fully absorbed by mixtures. This new methodcould improve the micro structure and mechanical properties of concrete and thecomprehensive performance of mixing equipment.
Firstly, the author analyzed the rheological properties of fresh concrete and provided atheoretical basis for determining the parameters of vibratory mixing equipment workingmechanism that ensure the complete destruction of the mixing mixtures structure as the goal.The shortcomings of ordinary forced mixing process were analyzed furtherly, and severalauxiliary methods to improve concrete performance were introduced.
The mechanisms that vibratory mixing method to improve mixing process and concreteperformance were detailed from six aspects, such as the mechanism of vibratory mixinginfluence on concrete rheological characteristics, the failure mechanism of cement aggregatesby using vibratory mixing method, the cleaning mechanism of coarse aggregate surface andenhancement mechanism of concrete bond strength by means of vibratory mixing, thegenerating mechanism of air bubble under the action of vibration, and the improvingmechanism of mixing inefficient zone during mixing process by means of vibratory mixing,the adaptability mechanism of vibratory mixing on multi material. The analysis found that thecomprehensive performance of concrete can be improved by means of vibratory mixing.
On the basis of theoretical analysis, a vertical shaft type vibratory mixer and a doublehorizontal shaft type vibratory mixer were designed. The vibration device and mixing device of the former mixer is independent from each other, but the latter is a whole. However, bothprototypes could realize vibrating action while mixing materials. The study of vibrationmixing on multi material’s adaptability was conducted in lab. The materials include ordinaryconcrete, roller compacted concrete (RCC), steel fiber reinforced concrete (SFRC), cementasphalt mortar (CA). Some tentative conclusions about reasonable value of the vibratory andmixing parameters were reached, and these will provide the basis for the industrializedapplication. The test results indicated that vibratory mixing has better adaptability to multimaterial and the concrete performance indexes are better than ordinary forced mixing. Thevertical shaft type vibratory mixer is more suitable for mixing materials with smaller particlesize, such as cement asphalt mortar, and the double horizontal shaft type vibratory mixer ismore suitable for mixing materials with larger particle size.
Based on the theoretical analysis and experimental study, the irrationality of the currentevaluation index system of mixing equipment was tested and analyzed in this paper, andsome suggestions for revising the current evaluation index system were put forward, such as,what kind of indexes will be needed in different situations, in order to improve the indexsystem.
In order to combine the research findings of theory and test with industrial practice, aindustrial prototype, a double horizontal shaft type vibratory mixer with1m3capacity, wasdesigned and manufactured, and the industrialization research was proceed. The studies showthat the prototype is stable and reliable during the working process with lower energyconsumption, vibration mixing time of45s and each index meets the national standard.Under the same conditions the strength of concrete produced by industrial prototype is15%higher than ordinary forced mixer, and the homogeneity of fresh concrete produced byindustrial prototype is better. In the case of reducing cement15%, the performance ofconcrete produced by industrial prototype is still meet the design requirements, so the effectof saving cement is obvious.
The research is assisted by National Science Found (50678026) and Major ScientificTechnological Innovation Special Fund Project in shaanxi province（2008ZKC01-16）.
论文首先分析了新拌混凝土结构-流变特性，为确定振动搅拌设备工作机构的几何、运动参数提供理论依据，指出各参数的选取需以保证搅拌筒内混合料结构的完全破坏为目标；进一步分析了混凝土搅拌过程及目前普遍采用的普通静力搅拌所存在的不足。
分六大方面，论文重点对混凝土振动搅拌方式改善搅拌过程及混凝土性能的机理进行了详细阐述，包括：振动搅拌对混凝土结构-流变特性的影响机理；振动搅拌对新拌混凝土中水泥团粒的破坏机理；振动搅拌对新拌混凝土中粗骨料表面的净化及其粘结强度的增强机理；振动搅拌对新拌混凝土中气相生成物的影响机理；振动搅拌对搅拌过程—低效区的改善机理；振动搅拌对多材料的适应性机理。理论分析认为，振动搅拌可综合提高搅拌设备及混凝土各项性能。
在理论分析的基础上，设计了两台试验样机：振动与静力搅拌相结合，但振动与搅拌工作装置分离的立轴式振动搅拌机，以及振动与静力搅拌工作装置相结合的一体式双卧轴振动搅拌机；进行了振动搅拌对普通混凝土、RCC、SFRC、CA砂浆等材料的适应性试验研究。初步得出了振动搅拌各参数的合理取值及匹配关系，为振动搅拌设备的工业化提供依据。试验结果表明：振动搅拌对多材料具有较好的适应性，各项性能指标均优于普通静力搅拌；立轴振动搅拌更适宜于骨料颗粒普遍较小的CA砂浆等材料的搅拌，双卧轴振动搅拌更适宜于较大粒径骨料的混凝土搅拌。
在理论分析和大量试验研究的基础上，针对现行搅拌设备评定指标体系的不合理性进行了试验证明和分析，并对修改现行搅拌设备评定指标提出了若干建议，给出在不同场合下需要增加的检验指标，旨在完善现行搅拌设备评定指标体系。
将理论及试验研究成果与工业实际相结合，试制了1m3双卧轴振动搅拌工业样机，并进行了工业化研究。研究表明：工业样机工作过程稳定可靠，各项指标满足国标要求，能耗较低，搅拌时间为45s；其他条件相同的情况下，工业样机生产的混凝土比普通静力搅拌机生产的混凝土强度提高15%以上，且新拌混凝土匀质性更好；工业样机在减少水泥15%时，混凝土性能仍满足设计要求，节约水泥效果明显。
本课题研究受到国家自然科学基金项目“混凝土振动拌和机理研究”（50678026）、陕西省重大科技创新专项资金项目“高效混凝土搅拌机的工业化研究”（2008ZKC01-16）资助。
At the present time, the focus of concrete research at home and abroad is materialgraduation, material performance and fresh concrete molding, but not the mixing process.The reason is that the mixing process involves mixing equipment, mixing materials andconstruction technology which belong to different disciplines, and easily divorced from eachother during the research process, so the study of mixing process is still at the macroscopicscale up to now, and this results in some problems, such as poor microstructure uniformity,low interfacial bond strength, low mixing speed, long mixing time, mixing velocitygradient and mixing inefficient zone and so on. The author in this paper presented a newvibratory mixing method with the combination of forced mixing, placing a vibration exciterthat designed by dynamic balance principle in the middle of mixing tube, and thevibrational energy from the exciter will be fully absorbed by mixtures. This new methodcould improve the micro structure and mechanical properties of concrete and thecomprehensive performance of mixing equipment.
Firstly, the author analyzed the rheological properties of fresh concrete and provided atheoretical basis for determining the parameters of vibratory mixing equipment workingmechanism that ensure the complete destruction of the mixing mixtures structure as the goal.The shortcomings of ordinary forced mixing process were analyzed furtherly, and severalauxiliary methods to improve concrete performance were introduced.
The mechanisms that vibratory mixing method to improve mixing process and concreteperformance were detailed from six aspects, such as the mechanism of vibratory mixinginfluence on concrete rheological characteristics, the failure mechanism of cement aggregatesby using vibratory mixing method, the cleaning mechanism of coarse aggregate surface andenhancement mechanism of concrete bond strength by means of vibratory mixing, thegenerating mechanism of air bubble under the action of vibration, and the improvingmechanism of mixing inefficient zone during mixing process by means of vibratory mixing,the adaptability mechanism of vibratory mixing on multi material. The analysis found that thecomprehensive performance of concrete can be improved by means of vibratory mixing.
On the basis of theoretical analysis, a vertical shaft type vibratory mixer and a doublehorizontal shaft type vibratory mixer were designed. The vibration device and mixing device of the former mixer is independent from each other, but the latter is a whole. However, bothprototypes could realize vibrating action while mixing materials. The study of vibrationmixing on multi material’s adaptability was conducted in lab. The materials include ordinaryconcrete, roller compacted concrete (RCC), steel fiber reinforced concrete (SFRC), cementasphalt mortar (CA). Some tentative conclusions about reasonable value of the vibratory andmixing parameters were reached, and these will provide the basis for the industrializedapplication. The test results indicated that vibratory mixing has better adaptability to multimaterial and the concrete performance indexes are better than ordinary forced mixing. Thevertical shaft type vibratory mixer is more suitable for mixing materials with smaller particlesize, such as cement asphalt mortar, and the double horizontal shaft type vibratory mixer ismore suitable for mixing materials with larger particle size.
Based on the theoretical analysis and experimental study, the irrationality of the currentevaluation index system of mixing equipment was tested and analyzed in this paper, andsome suggestions for revising the current evaluation index system were put forward, such as,what kind of indexes will be needed in different situations, in order to improve the indexsystem.
In order to combine the research findings of theory and test with industrial practice, aindustrial prototype, a double horizontal shaft type vibratory mixer with1m3capacity, wasdesigned and manufactured, and the industrialization research was proceed. The studies showthat the prototype is stable and reliable during the working process with lower energyconsumption, vibration mixing time of45s and each index meets the national standard.Under the same conditions the strength of concrete produced by industrial prototype is15%higher than ordinary forced mixer, and the homogeneity of fresh concrete produced byindustrial prototype is better. In the case of reducing cement15%, the performance ofconcrete produced by industrial prototype is still meet the design requirements, so the effectof saving cement is obvious.
The research is assisted by National Science Found (50678026) and Major ScientificTechnological Innovation Special Fund Project in shaanxi province（2008ZKC01-16）.
引文
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