聚丙烯发泡板材表面喷涂机理研究
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摘要
随着塑料工业的发展,塑料发泡板材的应用越来越广泛。但是由于塑料发泡板材表面性能的一些缺点,仍在限制塑料发泡板材的进一步的发展。本文利用表面喷涂技术,以发泡板材为基体,金属粉末为喷涂材料,通过喷涂的方法改变塑料板材表面的力学性能。
根据热力学守恒定律和传热学理论进行设计并确定了盒式加热器的功率、加热器的设定温度和加热器的尺寸。同时运用ANSYS软件中的热分析模块对板材厚度方向进行温度场模拟分析,验证了盒式加热器设计的合理性。最后加工出所需的盒式加热器,实验表明加热后的塑料板材表面能达到所需要的温度,符合设计要求。
运用流体力学理论,建立了在喷涂过程中喷嘴内流体的数学模型,根据喷嘴内流体的流动机理,确定了喷嘴的结构和尺寸,运用ANSYS分析软件中的应力分析模块对喷嘴进行模拟分析,确定了喷嘴锥角。最后设计加工出所需的喷涂装置,实验证实喷涂装置能够较好的在板材表面形成涂层。
对聚丙烯发泡板材表面以铁粉和铜粉为喷涂材料进行喷涂,通过调节挤出速度、加热器的设定温度、喷射流量参数进行喷涂实验,在参数相互匹配时,可以使塑料板材表面能够获得比较理想的金属涂层。对喷涂后的板材进行力学实验,其硬度、强度、耐磨性均有提高。
针对板材挤压成型工艺的特点,设计相应的加热和喷涂装置,调整挤出速度、加热器的设定温度、喷射流量参数,可以在板材表面得到致密的金属涂层。
With the development of plastic industry, the plastic foamed sheet is being used more and more widely. But plastic foamed sheet itself have some defects and restrict the development of it. Starting from the spray method: At first introduction of several spraying methods,then useing the principle of spray on the polypropylene foamed sheet. With polypropylene foamed sheet for the matrix and metallic powder as spray materials, to change the mechanical properties of the surface of the plastic foamed sheet.
Based on thermodynamic Energy conservation and the heat transfer theory .Then design the power of box heater and the set temperature of the box heater. Meanwhile,simulation of temperature in the thickness direction is made of using thermal analysis module in ANSYS software,which validates the rationality of the design of the box heater. The experiment shows that temperature on the plastic foamed sheet surface after heating by box heater can conform the design requirements.
According to fluid mechanics theory, established the mathematical model for the spray process of gas fluid in the spray nozzle was established.The new spray nozzles dimensions were designed based on the gas flow fluid in the spray nozzle.Numerical simulation analysis is made of to determine the nozzle cone angle using stress analysis module in ANSYS software.Finally, according to the design, the required spraying device isgiven out and the experiment shows that the new spray nozzle can achieve the ideal effect.
Through the experiments of spraying the materials iron and copper powder on the surface of polypropylene foam sheet,by adjusting the extrusion speed, heater temperature setting, injection flow parameters of spraying experiments, determine a parameter and then change the other parameters to acquire an ideal metal coating on the polypropylene foam sheet surface.The mechanics experiments on the surface of the pp show its hardness and strength and wear resistance were increased.
In response to the features of the technology plate extrusion molding, design the appropriate heating and spraying devices. Dense metal coating on the plastic plate surface can be acquired by adjusting the extrusion speed, the heating temperature and spraying flow parameters.
根据热力学守恒定律和传热学理论进行设计并确定了盒式加热器的功率、加热器的设定温度和加热器的尺寸。同时运用ANSYS软件中的热分析模块对板材厚度方向进行温度场模拟分析,验证了盒式加热器设计的合理性。最后加工出所需的盒式加热器,实验表明加热后的塑料板材表面能达到所需要的温度,符合设计要求。
运用流体力学理论,建立了在喷涂过程中喷嘴内流体的数学模型,根据喷嘴内流体的流动机理,确定了喷嘴的结构和尺寸,运用ANSYS分析软件中的应力分析模块对喷嘴进行模拟分析,确定了喷嘴锥角。最后设计加工出所需的喷涂装置,实验证实喷涂装置能够较好的在板材表面形成涂层。
对聚丙烯发泡板材表面以铁粉和铜粉为喷涂材料进行喷涂,通过调节挤出速度、加热器的设定温度、喷射流量参数进行喷涂实验,在参数相互匹配时,可以使塑料板材表面能够获得比较理想的金属涂层。对喷涂后的板材进行力学实验,其硬度、强度、耐磨性均有提高。
针对板材挤压成型工艺的特点,设计相应的加热和喷涂装置,调整挤出速度、加热器的设定温度、喷射流量参数,可以在板材表面得到致密的金属涂层。
With the development of plastic industry, the plastic foamed sheet is being used more and more widely. But plastic foamed sheet itself have some defects and restrict the development of it. Starting from the spray method: At first introduction of several spraying methods,then useing the principle of spray on the polypropylene foamed sheet. With polypropylene foamed sheet for the matrix and metallic powder as spray materials, to change the mechanical properties of the surface of the plastic foamed sheet.
Based on thermodynamic Energy conservation and the heat transfer theory .Then design the power of box heater and the set temperature of the box heater. Meanwhile,simulation of temperature in the thickness direction is made of using thermal analysis module in ANSYS software,which validates the rationality of the design of the box heater. The experiment shows that temperature on the plastic foamed sheet surface after heating by box heater can conform the design requirements.
According to fluid mechanics theory, established the mathematical model for the spray process of gas fluid in the spray nozzle was established.The new spray nozzles dimensions were designed based on the gas flow fluid in the spray nozzle.Numerical simulation analysis is made of to determine the nozzle cone angle using stress analysis module in ANSYS software.Finally, according to the design, the required spraying device isgiven out and the experiment shows that the new spray nozzle can achieve the ideal effect.
Through the experiments of spraying the materials iron and copper powder on the surface of polypropylene foam sheet,by adjusting the extrusion speed, heater temperature setting, injection flow parameters of spraying experiments, determine a parameter and then change the other parameters to acquire an ideal metal coating on the polypropylene foam sheet surface.The mechanics experiments on the surface of the pp show its hardness and strength and wear resistance were increased.
In response to the features of the technology plate extrusion molding, design the appropriate heating and spraying devices. Dense metal coating on the plastic plate surface can be acquired by adjusting the extrusion speed, the heating temperature and spraying flow parameters.
引文
[1]徐滨士,朱绍华,刘世参.材料表面工程[M].哈尔滨工业大学出版社,2005
[2]徐滨士,刘世参.表面工程[M].机械工业出版社,2000:33-67
[3]郦振声,杨明安.现代表面工程技术[M].机械工业出版社,2007
[4]王新洪,邹增大,曲仕尧.表面熔融凝固强化技术[M].化学工业出版社,2005:88-98
[5]吴涛等.热喷涂技术现状与发展[J].国外金属热处理,2005,26(4):2-5
[6]张平.热喷涂材料[M].国防工业出版社,2006:44-66
[7]林启昭.高分子复合材料及其应用[M].中国铁道出版社,1988
[8] Leaversuch, R. D. Wood fiber composites build promising role in extrusion[J].Modern Plastics,2000,77(1212)56-59
[9] K. Okemah. Improved interaction between wood and synthetic polymers in wood/polymer composites[J].Wood Science and Technology,1996,30(3):197- 205
[10]秦特夫.改善木塑复合材料界面相容性的途径[J].世界林业研究,1998:12 (3):46-51
[11]吴舜英,徐敬一.泡沫塑料成型[M].化学工业出版社,2000:68-124
[12] Cunha, A.G, Covas,J.A,Oliveira.Optimization of polymer extrusion with genetic algorithms[J].IMA Journal of Mathematics Applied in Business and Industry,1998,9(3):207-277
[13]闫烨,代芳.2007年我国热塑性工程塑料进展[J].工程塑料应用,2008,36(04):69-74
[14]张振,赵志鸿.2008年我国热固性工程塑料进展[J].工程塑料应用,2009,37(05):76-80
[15]杨伟才.工程塑料行业十年发展回顾与展望[J].工程塑料应用,2008,36(9):4-6
[16]陈佰全,戴文利,汤红霞.聚丙烯发泡材料的研究进展[J].塑料制造,2006,12(149):55-58
[17]陈乐怡.发泡聚烯烃技术发展[J].中国塑料,1990,4(4):13-16
[18]张旭峰,王澜.发泡聚丙烯材料的研究进展[J].广东塑料,2005,3(8):34-37
[19] C.B. Park,D.F. Baldwin,N.P. Suh. Effect of the pressure drop rate on cellnucleation in continuous processing of microcellular polymers[J].Polymer Engineering and science,200435(5):432-440
[20] C.B. Park,D.F. Baldwin,N.P. Suh. An extrusion system for the processing of microcellular polymer sheet: shaping and cell growth control[J]. Polymer Engineering and science,1996,36(10):1425-1435
[21]张倩,何继敏.聚丙烯结构发泡注塑成型研究进展[J],塑料科技,2008,36(5):78-81
[22]董力群等.塑料挤出成型设备的发展现状[J].中国塑料,1998,12(2):11-19
[23]胡志鹏,杨燕.中国塑料机械市场发展现状与趋势[J].工程塑料应用,2004,32(4):56-59
[24]赵敏,高俊刚,邓奎林,赵兴艺.改性聚丙烯新材料[M].化学工业出版社,2002:23-89
[25]张正荣.传热学[M].高等教育出版社,1982
[26]张有智,付涛,邢俊.温控加热炉的设计与应用[J].宽厚板,2009,2(2):43-44
[27]李虹.电加热器的多回路温度自动控制系统[J].贵州化工,2002,27(2):43-45
[28] Lefebvre,A.H.Atomization and sprays[M].CRC,1989
[29]曹建明.喷雾学[M].机械工业出版社,2005
[30] I.Finnie, J.Wolak and Y.Kabil.Erosion of metals by solid particles[J].Wear,1967, (2):682-700
[31]康进兴,赵文轸,朱金华.材料抗冲蚀性的研究进展[J].材料保护,2001,34(10):22-23
[32]沈国良.喷丸清理技术[M].化学工业出版社,2004
[33]孙家枢.金属的磨损[M].冶金工业出版社,1986
[34]林福严,曲敬信,陈华辉.磨损理论与抗磨技术[M].科学出版社,1993
[35] A. V. Levy. The platelet mechanism of erosion of ductile metals[J]. Wear,1986, 10(8):1-1
[36] T. S. Eyre. Treatise on materials science and technology[J]. Wear,1979, (13):363-365
[37]曾德麟.粉末冶金材料[M].冶金工业出版社,1969
[38]邱关明.新型陶瓷[M].兵器工业出版社,1992:23-30
[39]金志浩,高积强,乔冠军.工程陶瓷材料[M].西安交通大学出版社,2000
[40]潘牧,罗志平.材料的冲蚀问题[J].材料科学与工程,1999,17(3):92-96
[41]Lee Tai-Chiu,Deng Jianxin. Ultrasonic erosion of whisker-reinforced ceramic[J].Ceramics International.2001,27(7):755-760
[42]叶敬棠,柳兆荣,许世雄,吴正.流体力学[M].复旦大学出版社,1987,509-555
[43]刘勇,田保红,刘素芹.先进材料表面处理和测试技术[M].科学出版社,2008:78-89
[44]李国英.表面工程手册[M].机械工业出版社,1997,3-1,3-112
[45]王勖成,邵敏.有限单元法基本原理和数值分析[M].北京:清华大学出版社,1997
[46]王勖成.有限单元法[M].清华大学出版社,2002,351-468
[47] J.G. A.Biter. A study of erosion phenomena, Part 1[J].Science direct,1963,6(1): 5-21
[48]薛群基,刘惠文.陶瓷摩擦学,陶瓷的摩擦与磨损.摩擦学学报,1995,15(4):376- 384
[2]徐滨士,刘世参.表面工程[M].机械工业出版社,2000:33-67
[3]郦振声,杨明安.现代表面工程技术[M].机械工业出版社,2007
[4]王新洪,邹增大,曲仕尧.表面熔融凝固强化技术[M].化学工业出版社,2005:88-98
[5]吴涛等.热喷涂技术现状与发展[J].国外金属热处理,2005,26(4):2-5
[6]张平.热喷涂材料[M].国防工业出版社,2006:44-66
[7]林启昭.高分子复合材料及其应用[M].中国铁道出版社,1988
[8] Leaversuch, R. D. Wood fiber composites build promising role in extrusion[J].Modern Plastics,2000,77(1212)56-59
[9] K. Okemah. Improved interaction between wood and synthetic polymers in wood/polymer composites[J].Wood Science and Technology,1996,30(3):197- 205
[10]秦特夫.改善木塑复合材料界面相容性的途径[J].世界林业研究,1998:12 (3):46-51
[11]吴舜英,徐敬一.泡沫塑料成型[M].化学工业出版社,2000:68-124
[12] Cunha, A.G, Covas,J.A,Oliveira.Optimization of polymer extrusion with genetic algorithms[J].IMA Journal of Mathematics Applied in Business and Industry,1998,9(3):207-277
[13]闫烨,代芳.2007年我国热塑性工程塑料进展[J].工程塑料应用,2008,36(04):69-74
[14]张振,赵志鸿.2008年我国热固性工程塑料进展[J].工程塑料应用,2009,37(05):76-80
[15]杨伟才.工程塑料行业十年发展回顾与展望[J].工程塑料应用,2008,36(9):4-6
[16]陈佰全,戴文利,汤红霞.聚丙烯发泡材料的研究进展[J].塑料制造,2006,12(149):55-58
[17]陈乐怡.发泡聚烯烃技术发展[J].中国塑料,1990,4(4):13-16
[18]张旭峰,王澜.发泡聚丙烯材料的研究进展[J].广东塑料,2005,3(8):34-37
[19] C.B. Park,D.F. Baldwin,N.P. Suh. Effect of the pressure drop rate on cellnucleation in continuous processing of microcellular polymers[J].Polymer Engineering and science,200435(5):432-440
[20] C.B. Park,D.F. Baldwin,N.P. Suh. An extrusion system for the processing of microcellular polymer sheet: shaping and cell growth control[J]. Polymer Engineering and science,1996,36(10):1425-1435
[21]张倩,何继敏.聚丙烯结构发泡注塑成型研究进展[J],塑料科技,2008,36(5):78-81
[22]董力群等.塑料挤出成型设备的发展现状[J].中国塑料,1998,12(2):11-19
[23]胡志鹏,杨燕.中国塑料机械市场发展现状与趋势[J].工程塑料应用,2004,32(4):56-59
[24]赵敏,高俊刚,邓奎林,赵兴艺.改性聚丙烯新材料[M].化学工业出版社,2002:23-89
[25]张正荣.传热学[M].高等教育出版社,1982
[26]张有智,付涛,邢俊.温控加热炉的设计与应用[J].宽厚板,2009,2(2):43-44
[27]李虹.电加热器的多回路温度自动控制系统[J].贵州化工,2002,27(2):43-45
[28] Lefebvre,A.H.Atomization and sprays[M].CRC,1989
[29]曹建明.喷雾学[M].机械工业出版社,2005
[30] I.Finnie, J.Wolak and Y.Kabil.Erosion of metals by solid particles[J].Wear,1967, (2):682-700
[31]康进兴,赵文轸,朱金华.材料抗冲蚀性的研究进展[J].材料保护,2001,34(10):22-23
[32]沈国良.喷丸清理技术[M].化学工业出版社,2004
[33]孙家枢.金属的磨损[M].冶金工业出版社,1986
[34]林福严,曲敬信,陈华辉.磨损理论与抗磨技术[M].科学出版社,1993
[35] A. V. Levy. The platelet mechanism of erosion of ductile metals[J]. Wear,1986, 10(8):1-1
[36] T. S. Eyre. Treatise on materials science and technology[J]. Wear,1979, (13):363-365
[37]曾德麟.粉末冶金材料[M].冶金工业出版社,1969
[38]邱关明.新型陶瓷[M].兵器工业出版社,1992:23-30
[39]金志浩,高积强,乔冠军.工程陶瓷材料[M].西安交通大学出版社,2000
[40]潘牧,罗志平.材料的冲蚀问题[J].材料科学与工程,1999,17(3):92-96
[41]Lee Tai-Chiu,Deng Jianxin. Ultrasonic erosion of whisker-reinforced ceramic[J].Ceramics International.2001,27(7):755-760
[42]叶敬棠,柳兆荣,许世雄,吴正.流体力学[M].复旦大学出版社,1987,509-555
[43]刘勇,田保红,刘素芹.先进材料表面处理和测试技术[M].科学出版社,2008:78-89
[44]李国英.表面工程手册[M].机械工业出版社,1997,3-1,3-112
[45]王勖成,邵敏.有限单元法基本原理和数值分析[M].北京:清华大学出版社,1997
[46]王勖成.有限单元法[M].清华大学出版社,2002,351-468
[47] J.G. A.Biter. A study of erosion phenomena, Part 1[J].Science direct,1963,6(1): 5-21
[48]薛群基,刘惠文.陶瓷摩擦学,陶瓷的摩擦与磨损.摩擦学学报,1995,15(4):376- 384