同向双螺杆挤出机固体输送段的影响因素研究
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摘要
啮合同向双螺杆挤出机由于其较为优异的输送能力、自洁作用和混炼性能,在聚合物加工过程中起到越来越重要的作用,而目前对双螺杆挤出过程的研究大多集中在熔融段和熔体输送段,对固体输送段的研究较少,尤其是加工过程中输送量和功耗的影响因素研究,缺乏较为实用的固体输送方程。
本文通过响应曲面实验设计,选择粒料、粉料、长纤维填充物料和无机粉体高填充物料等四种典型物料进行固体输送实验,选择固体输送量和主机功率消耗为目标函数,选择操作参数、螺纹元件结构参数、物料参数等作为影响因素,进行实验研究和结果分析,得到了每种物料在不同工况下的固体输送方程和功耗方程,分析各个因素对目标函数的影响大小和各因素之间的交互影响。
运用数学建模方法,基于实验对四种物料所建立的Φ34单导程构型固体输送方程和变导程构型固体输送方程,均具有高度的准确性,能够很好的预测实际固体输送量和功耗,各方程的预测准确性均达到90%以上,部分方程预测准确性可达95%以上。
研究结果表明,在粒料的单导程构型固体输送当中,影响功耗和输送能力的最主要因素是螺旋升角和物料粒径的大小。在固体输送段使用变导程构型,大多数工况都产生了固相堵塞,所以对于粒料的输送,不宜采取变导程构型。对于粉料的固体输送,无论是使用单导程构型还是变导程构型,主机转速对输送量的作用最为明显。在单导程构型粉体物料输送中,螺旋升角对功耗影响最大,在变导程构型输送中,主机转速对功耗影响最大。在同样的工况下,单导程构型的输送能力更强,且功耗更小。填充长纤维的物料其输送具有自身的特点,单导程输送中,螺旋升角对功耗的影响最大,而螺杆填充率对输送量的影响最大；使用变导程构型输送,主机转速对螺杆的功耗和输送量影响最大。在同样的工况下,变导程构型的输送能力更强,功耗更大。在单导程构型输送无机粉体高填充物料过程中,主机转速对功耗的影响最大,螺杆填充率对输送量的影响最大；在变导程构型输送时,主机转速对功耗和输送量的影响均为最大。在同样工况下,变导程构型的输送能力更强,功耗更大。
Co-rotating twin screw extruders are playing more important role in polymer processing for their excellent transmission capacity, self-cleaning and mixing property. At present, there are a lot of literatures on melting and melting convey, but few articles on the stuty of solid convey especially on factors of output and power, lack of equation in solid convey zone.
In this study, RSM(Response surface methodolygy) experiment were designed to form equation of solid convey, in the experiment design, solid pellets, powders, long-fiber materials and high inorganic powder fillers are were used, output of solid convey and power were choosed as objective functions while operating parameters, structural patameters of screw element and materials paratemeters were choosed as effective factors. After experiments analysis and research, quadratic multinomial equations of output and power equations were built, from these equations, effect of main factors and their corresponding relationships were discussed.
Based on experiment studies, solid convey equations onφ34 single lead configuration and vary lead configurations of four materials were built by mathematical molding method. These equations were highly accurate and could excellently predicted the practical output and power consumption, forecast accuracy of all these equations are more than 90% and some of them could be more than 95%.
From results of research, some conclusions can be derived:in the solid pellets convey, when using single lead configuration, the main factors on power and output were respectly helix angle and diameter of pellets, when using vary lead configuration, solid block would appear, so vary lead configuration were not suitable in solid pellets convey; in powder convey, whatever using two configurationss, the main factor on output was rotating speed, while the main factors on power were respectively helix angle of screw elements and rotating speed, it showed that compared to vary lead configuration, single lead configuration had harder transmission capacity and lower power consumption; in convey of long-fiber materials, when using single lead configuration, the main factors on output and power were respectively filling rate and helix angle of screw element, when using vary lead configuration, main factors on output and power were both rotating speed, compared to single lead configuration, vary lead configuration had harder transmission and higher power consumption; in convey of high inorganic powder fillers, when using single lead configuration, the main factors on output and power were repectively filling rate of screw elements and rotating speed, when using vary lead configuration, main factors on output and power were both rotating speed, compared to single lead configuration, vary lead configuration had harder transmission capacity and higher power consumption.
本文通过响应曲面实验设计,选择粒料、粉料、长纤维填充物料和无机粉体高填充物料等四种典型物料进行固体输送实验,选择固体输送量和主机功率消耗为目标函数,选择操作参数、螺纹元件结构参数、物料参数等作为影响因素,进行实验研究和结果分析,得到了每种物料在不同工况下的固体输送方程和功耗方程,分析各个因素对目标函数的影响大小和各因素之间的交互影响。
运用数学建模方法,基于实验对四种物料所建立的Φ34单导程构型固体输送方程和变导程构型固体输送方程,均具有高度的准确性,能够很好的预测实际固体输送量和功耗,各方程的预测准确性均达到90%以上,部分方程预测准确性可达95%以上。
研究结果表明,在粒料的单导程构型固体输送当中,影响功耗和输送能力的最主要因素是螺旋升角和物料粒径的大小。在固体输送段使用变导程构型,大多数工况都产生了固相堵塞,所以对于粒料的输送,不宜采取变导程构型。对于粉料的固体输送,无论是使用单导程构型还是变导程构型,主机转速对输送量的作用最为明显。在单导程构型粉体物料输送中,螺旋升角对功耗影响最大,在变导程构型输送中,主机转速对功耗影响最大。在同样的工况下,单导程构型的输送能力更强,且功耗更小。填充长纤维的物料其输送具有自身的特点,单导程输送中,螺旋升角对功耗的影响最大,而螺杆填充率对输送量的影响最大；使用变导程构型输送,主机转速对螺杆的功耗和输送量影响最大。在同样的工况下,变导程构型的输送能力更强,功耗更大。在单导程构型输送无机粉体高填充物料过程中,主机转速对功耗的影响最大,螺杆填充率对输送量的影响最大；在变导程构型输送时,主机转速对功耗和输送量的影响均为最大。在同样工况下,变导程构型的输送能力更强,功耗更大。
Co-rotating twin screw extruders are playing more important role in polymer processing for their excellent transmission capacity, self-cleaning and mixing property. At present, there are a lot of literatures on melting and melting convey, but few articles on the stuty of solid convey especially on factors of output and power, lack of equation in solid convey zone.
In this study, RSM(Response surface methodolygy) experiment were designed to form equation of solid convey, in the experiment design, solid pellets, powders, long-fiber materials and high inorganic powder fillers are were used, output of solid convey and power were choosed as objective functions while operating parameters, structural patameters of screw element and materials paratemeters were choosed as effective factors. After experiments analysis and research, quadratic multinomial equations of output and power equations were built, from these equations, effect of main factors and their corresponding relationships were discussed.
Based on experiment studies, solid convey equations onφ34 single lead configuration and vary lead configurations of four materials were built by mathematical molding method. These equations were highly accurate and could excellently predicted the practical output and power consumption, forecast accuracy of all these equations are more than 90% and some of them could be more than 95%.
From results of research, some conclusions can be derived:in the solid pellets convey, when using single lead configuration, the main factors on power and output were respectly helix angle and diameter of pellets, when using vary lead configuration, solid block would appear, so vary lead configuration were not suitable in solid pellets convey; in powder convey, whatever using two configurationss, the main factor on output was rotating speed, while the main factors on power were respectively helix angle of screw elements and rotating speed, it showed that compared to vary lead configuration, single lead configuration had harder transmission capacity and lower power consumption; in convey of long-fiber materials, when using single lead configuration, the main factors on output and power were respectively filling rate and helix angle of screw element, when using vary lead configuration, main factors on output and power were both rotating speed, compared to single lead configuration, vary lead configuration had harder transmission and higher power consumption; in convey of high inorganic powder fillers, when using single lead configuration, the main factors on output and power were repectively filling rate of screw elements and rotating speed, when using vary lead configuration, main factors on output and power were both rotating speed, compared to single lead configuration, vary lead configuration had harder transmission capacity and higher power consumption.
引文
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[2]Schneider. Uber eine neue Methode zur kinetischen Untersuchung der Perlpolymerisation[J]. Die Makromolekulare Chemie,1969,125(1):213～219.
[3]Zehev,Tadmor. Melting in plasticating extuders theory and experiments[J]. Polymer Engineering & Science,1967,7(3):198～217.
[4]Chung C I. Plasticating single-screw exrtusion theory[J]. Polymer Engineering & Science,1971, 11(2):93～98.
[5]W Tedder. SPE,1971,26(5):32.
[6]E. Broyer,Tadmor E B A Z. Solids conveying in screw extruders part Ⅰ:A modified isothermal model[J]. Polymer Engineering & Science,1972,12(1):12～24.
[7]E Broyer, Tadmor. Solids conveying in screw extruders part Ⅱ:Non isothermal model[J]. Polymer Engineering & Science,1972,12(5):378～386.
[8]Fuhua Zhu, Liqi Chen. Studies on the theory of single screw plasticating extrusion. Part Ⅰ:A new experimental method for extrusion[J]. Polymer Engineering & Science,1991,31(15):1113～1116.
[9]Shizeng Fang,Fuhua Zhu, Liqi Chen. Studies on the theory of single screw plasticating extrusion. Part Ⅱ:Non-plug flow solid conveying[J]. Polymer Engineering & Science,1991,31(15):1117～1122.
[10]朱复华.单螺杆塑化挤出理论的研究[J].高分子材料科学与工程,1986,(3)：1～7.
[11]江顺亮,朱复华.非塞流固体输送理论的简化 [J].中国塑料,1995,9(6)：60～63.
[12]B. Maxwell, G G.Gogos, Structure-property modifications by fabrication operations[J]. Polymer Engineering and Science,1964,4(3):165～168.
[13]N. M. Smith, J Parnaby. Bulk density versus hydrostatic pressure characteristics of plastics in powder and pellet form[J]. Polymer Engineering & Science,1980,20(12):830～833.
[14]Friehe C A. Static coefficients of friction for polyethylenes[J]. Polymer Engineering & Science, 1966,6(2):135～141.
[15]Kun S. Hyun, Mark A Spalding. Bulk density of solid polymer resins as a function of temperature and pressure[J]. Polymer Engineering & Science,1990,30(10):571～576.
[16]D.Q.Qiu P Prentice. Influence of pressure on bulk density of polymer solid granules at different temperatures[J]. Advances in Polymer Technology,1998,17(1):23～26.
[17]Chii-Guang Hwang James M. McKelvey. Solid bed compaction and frictional drag during melting in a simulated plasticating extruder[J]. Advances in Polymer Technology,1989,9(3):227～251.
[18]C. I. Chung, W. J. Hennessey, M. H. Tusim. Frictional behavior of solid polymers on a metal surface at processing conditions [J]. Polymer Engineering & Science,1977,17(1):9～20.
[19]Mark A. Spalding, Donald E. Kirkpatrick, Kun S. Hyun. Coefficients of dynamic friction for low density polyethylene[J]. Polymer Engineering & Science,1993,33(7):423～430.
[20]Mark A. Spalding, Kun S. Hyun, Steven R. Jenkins and Donald E. Kirkpatrick. Coefficients of dynamic friction and the mechanical melting mechanism for vinylidene chloride copolymers[J]. Polymer Engineering & Science,1995,35(23):1907～1916.
[21]E. Gamache, P. G. Lafleur, C. Peiti and B. Vergnes. Measurement of the coefficient of dynamic friction at extrusion processing conditions[J]. Polymer Engineering & Science,1999,39(9):1604～ 1613.
[22]江顺亮,朱复华.单螺杆挤出全过程三段七区模型的计算机模拟及软件研制[J].中国塑料,2003,17(1)：100～105.
[23]邢应生,朱复华,江顺亮.单螺杆挤出过程固体输送段的数值模拟[J].中国塑料,2004,18(10)：83～87.
[24]瞿金平.聚合物塑化挤出新概念[J].华南理工大学学报,1992,20(4)：1～4.
[25]田雨.动态挤出机固体输送理论的研究[硕士].华南理工大学,1996.
[26]石宝山,瞿金平等.振动力场作用下的单螺杆挤出机固体输送理论[J].化工学报,2006,57(11)：2568～2576.
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