新型实验用密炼机的设计及实验研究
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摘要
随着橡塑工业及其它高分子材料行业的迅速发展，密炼机在高分子材料加工中所占的地位越来越重要，用途越来越广泛；同时，对密炼机的性能要求也越来越苛刻。特别是近年来，随着全钢子午线轮胎、丁基胶内胎、切割V带、橡胶油封等新产品的开发和广泛使用，再加上橡塑共混制品的不断开发和应用，对密炼机的性能提出了更高的要求。因为密炼机性能的好坏直接影响到混炼胶的质量，也关联着制品的使用性能和寿命。目前各国都相继研制开发了各种新型密炼机，调距式密炼机就是其中之一。因此，结合行业的趋势，本人主要进行了实验用调距式密炼机的研究。本文主要完成工作如下：
1、本人在广泛的查阅国内外大量文献的基础上，完成了该新型调距式密炼机实验样机主要零部件以及电器控制系统的设计和制造；
2、本文对所设计的新型调距式密炼机的混炼过程进行了系统的理论分析和实验研究，在此基础上建立了该密炼机混炼过程的物理模型和数学模型，并对其进行探讨；
3、在相同的配方、相同的工艺条件下，分别在普通剪切型密炼机、啮合型密炼机和新型调距式密炼机上进行了静电复印机传送带胶料、全钢子午胎胶料的对比试验，并对试验数据进行了分析和研究；
4、在试验方案上，采用常规试验对新型调距式密炼机的混炼特性(最大功率、单位能耗、混炼时间、生产能力、排胶温度)和所混炼的胶料性能指标(300％定伸应力，拉伸强度，扯断伸长率，硬度等)进行了分析。同时，在试验分析的基础上，定性地讨论了工艺因素的影响，确定出最优化工艺条件，并进行了综合分析。
With rapid development of rubber and plastic industry as well as other polymer material industry,the internal mixer is playing a greater and greater role in polymer material production,and there is a higher requirement for the performance of the internal mixer. Especially in recent years,the development and utilization of many new products such as radical wire tire,acrylonitrile butyl rubber tube,raw edge V-belt and rubber oil seal as well as the development of rubber and plastic mixtures deserve perfect function of the internal mixer. This is because the performance of the internal mixer is related to the quality of mixed stock,and also to the performance and longevity of production. The developing of a new kind of clearance internal mixer can deal with the problem.
The main work and achievement of this paper are as follows:1.On the basis of collecting a vast amount of domestic and overseas data,the author design and made a clearance internal mixer. Especially,the author also conducted a thoroughgoing and painstaking ideological work about the mixing mechanism of clearance internal mixer.
2. Here,the author studied the theory and made experiments to the mixing process have the clearance internal mixer and formed physical model and the relative mathematical model.
3.Using the same recipe and technological facts,the author compared the difference between tow kinds of rubber products in clearance internal mixer on the operation.
4.Taking use of experiments carried out,the parameters such as maximum power,unit energy consumption,the time of the processing of mixing,the capacity of production,exited rubber temperature,was studied. The optimum condition can be obtained from the discussing the effect of the recipe factors (rubber,filler,softener and their mixture ratio) and technological factors. The author constructed the math model of the clearance internal mixer. Further,on the basis of the conclusions of the mathematical models of the clearance internal mixer were attempted to be building in terms of statistical theory. Through the models it was found that the inherent laws in the process of mixing of the clearance internal mixer.
1、本人在广泛的查阅国内外大量文献的基础上，完成了该新型调距式密炼机实验样机主要零部件以及电器控制系统的设计和制造；
2、本文对所设计的新型调距式密炼机的混炼过程进行了系统的理论分析和实验研究，在此基础上建立了该密炼机混炼过程的物理模型和数学模型，并对其进行探讨；
3、在相同的配方、相同的工艺条件下，分别在普通剪切型密炼机、啮合型密炼机和新型调距式密炼机上进行了静电复印机传送带胶料、全钢子午胎胶料的对比试验，并对试验数据进行了分析和研究；
4、在试验方案上，采用常规试验对新型调距式密炼机的混炼特性(最大功率、单位能耗、混炼时间、生产能力、排胶温度)和所混炼的胶料性能指标(300％定伸应力，拉伸强度，扯断伸长率，硬度等)进行了分析。同时，在试验分析的基础上，定性地讨论了工艺因素的影响，确定出最优化工艺条件，并进行了综合分析。
With rapid development of rubber and plastic industry as well as other polymer material industry,the internal mixer is playing a greater and greater role in polymer material production,and there is a higher requirement for the performance of the internal mixer. Especially in recent years,the development and utilization of many new products such as radical wire tire,acrylonitrile butyl rubber tube,raw edge V-belt and rubber oil seal as well as the development of rubber and plastic mixtures deserve perfect function of the internal mixer. This is because the performance of the internal mixer is related to the quality of mixed stock,and also to the performance and longevity of production. The developing of a new kind of clearance internal mixer can deal with the problem.
The main work and achievement of this paper are as follows:1.On the basis of collecting a vast amount of domestic and overseas data,the author design and made a clearance internal mixer. Especially,the author also conducted a thoroughgoing and painstaking ideological work about the mixing mechanism of clearance internal mixer.
2. Here,the author studied the theory and made experiments to the mixing process have the clearance internal mixer and formed physical model and the relative mathematical model.
3.Using the same recipe and technological facts,the author compared the difference between tow kinds of rubber products in clearance internal mixer on the operation.
4.Taking use of experiments carried out,the parameters such as maximum power,unit energy consumption,the time of the processing of mixing,the capacity of production,exited rubber temperature,was studied. The optimum condition can be obtained from the discussing the effect of the recipe factors (rubber,filler,softener and their mixture ratio) and technological factors. The author constructed the math model of the clearance internal mixer. Further,on the basis of the conclusions of the mathematical models of the clearance internal mixer were attempted to be building in terms of statistical theory. Through the models it was found that the inherent laws in the process of mixing of the clearance internal mixer.
引文
[1] 汪传生博士论文《同步转子密炼机混炼橡胶的理论和实验研究》
[2] James L. White"Development of Interal Mixer Technology of the Rubber Industry", Rubb. Chem. Tech., 1992, 65(3): 527, 刘安祥译，橡胶技术与装备，1994, 5: 11, 1994, 6: 23, 1995, 1: 13
[3] F. Kempter, German279, 649(1914)
[4] F. Kempter, German 280, 757 (1914)
[5] J. E. Pointon, U. S. 1, 138, 410(May4, 1915)
[6] F. H. Banbury(to Birmingham Iron Foundry), U. S. 1, 200, 070(Oct.3, 1916)
[7] 周彦豪编《聚合物加工流变学基础》，1988年3月，第1版，西安交通大学出版社
[8] 朝田充纪著“橡胶混炼机的新技术”，1987，3：35，李汉堂译，轮胎研究与开发，1989，2：46
[9] Dr. Samir Majumdar著, Rubb. News, 1996, 12: 29,姚琳译“密炼机混炼”，轮胎研究与开发，1997, 2: 37
[10] F. H. Banbury(to Birmingham Iron Foundry), U. S. 1, 512, 813 (Oct. 21, 1924)
[11] K. Frei, German 717, 687(1942)
[12] K. Frei, U. S. 2, 415, 091(Feb. 4, 1947)
[13] E. H, Ford (to Patterson Fowndry & Machine), U. S. 2, 559, 418(July 3, 1951)
[14] N. Sato, M. Miyaoko, S. Yamasaki, K. Inoue, A. Kuriyama, T. Fukui, T. Asia, K. Nakajimnd T. Maski((to Bridgestone Tire and Kobe Stell, Ltd.)U. S., 4, 284, 385 (Aug. 18, 1981)
[15] N. Sato, M. Miyaoko, S. Yamasaki, K. Inoue, A. Kuriyama, T. Fukai, and T. Asia(to Birdge-sone Tire and Kobe Steel), U. S. 4, 300, 838(Nov 17, 1981)
[16] K. Inoue, T. Fukia, T. Asia, Nakajima and A. Kurigama(to Kabushiki Kaishu Kobe Seibo Sho), U. S. 4, 456, 381(June26, 1984)
[17] N. O. Nortey(to Farrel Corporation), U. S. 4, 714, 350(Dec. 22, 1987)
[18] N. O. Nortey(to Farrel Corporation), U. S. 4, 744, 668(May 17, 1988)
[19] T. Asai and K. Hagiwara(to Rabushiki Kaishu Kobe Seiko Sho), U. S. 4, 718, 771(June 12, 1988)
[20] A. Kuriyama (to kabushiki Kaishu Kobe Seiko Sho), U. S. 4, 824, 259(April 25, 1989)
[21] G. C. Passoni (to Pomini Farrel S. P. A.), U. S. 4, 775, 240 (Oct.4, 1988)
[22] L. Pomini S. Crespi"Mixer with Variable Intermeshing Clearnce", Rubb. World, 1992, 4: 2
[23] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[24] 詹茂盛，纪冰，赵嘉澍等“销钉密炼室的混炼特性”，橡胶技术与装备，1988，1：18
[25] 赵嘉澍，汪传生，纪冰等“同步转子的试验研究”，橡胶技术与装备，1991，6：1
[26] 刘安祥，汪传生，赵嘉澍等“对同步转子密炼机混炼各种胶料的性能的研究”，橡胶技术与装备，1995，4：1
[27] 杨顺根“Pomini公司的密炼机及其新开发的HDM转子”，橡机工业，1995，4：11
[28] G. C. Passoni (to Pomini Farrel S. P. A.), U. S. 4, 775, 240 (Oct.4, 1988)
[29] L. Pomini S. Crespi"Mixer with Variable Intermeshing Clearnce", Rubb. World, 1992, 4: 2, 橡胶技术与装备, 1995, 4: 1
[30] 纪冰，胡海明，汪传生等“同速同向转子密炼机的研究”，合成橡胶工业，1997，4：207，CA，1997，9：644
[31] 唐国俊，李健宾(华南工学院)主编《橡胶机械设计》上册，1984年6月，第1版，化学工业出版社
[32] 陈国镇译“具有良好分散效果的MS型加压捏炼机”，橡胶技术与装备，1989，3：49(原文为日本《聚合物文摘》，1987，3)
[33] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[34] 赵嘉澍，詹茂盛，纪冰，蒋立达“密炼机转子改造的新型转子——销钉转子”，橡胶技术与装备，1987，1：19
[35] 方浩庭“密炼机销钉转子在生产中的应用”，橡胶技术与装备，1987，1：22
[36] 赵嘉澍，詹茂盛，李木松等“销钉转子的混炼功率”，橡胶工业，1988，2：95
[37] 詹茂盛，赵嘉澍，纪冰等“销钉密炼室的混炼功率和排胶温度”，橡胶技术与装备，1987，4：1
[38] 詹茂盛，赵嘉澍，纪冰等“销钉密炼室密炼机的试验研究”，特种橡胶制品，
[39] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[40] 大连橡胶塑料机械研究编《橡胶塑料机械》，1986年9月，第1版，机械工业出版社
[41] 杨伟川“Guix-50U密炼机的简介”，橡胶技术与装备，1992，5：16
[42] 林宝善“国产密炼机的简要特征”，橡胶技术与装备，1992，5：56
[43] 阎锦涛“XM-270／20型密炼机曲拐式锁紧装置及其自锁角的计算”，橡胶技术与装备，1988，4：29
[44] 李纪新译“混炼过程的温度控制”，橡胶技术与装备，1985，2：24
[45] J. K. Kim and J. L. Whiter "An Experimental and Theoretical Study of Strvation Effects on Flow and Mixing Elastomers in an Internal Mixer", Nihon Reoroji Gakkaishi, 1989, 17(4): 203
[46] J. K. Kim, J. L. White, K. Min and W. Szydlowski "Simulation of Flow and Mixing in an Internal Mixer", Int. Polym. Proc., 1989, 44(1): 9
[47] J. L. White and J. K. Kim "Design Consideration for Internal Mixers: Mechanism of Motion of Elastomers in machines with Non-Intermeshing Rotors" , Kautsch. Gummi Kunstst. 1991, 44(3): 242
[48] K. Yagi and K. Kawanishi, Int. Polym. Proc., 1990, 5: 163
[49] 黄元昌译“英国法勒尔(Farrel)公司的Banbury密炼机”，橡胶工程信息，1999，10：13(原文英国《Farrel Banbury Mixer》，样本，1999．6)
[50] P. K. Freakley and W. Y. Wan Idris "Visualization of Flow During the Processing of Rubber in an Interal Mixer", Rubb. Chem. Tech. 1979, 52: 134
[51] J. J. Cheng and I. Manas-Zlocower"Hydrodynamic Analysis of a Banbury Mixer-2-D Flower Simulations for the Entire Mixing Champer", Polym. Eng. Sci., 1989, 29(5): 1059
[52] J. J. Cheng and I. Manas-Zlocower "Flow Field Characterization in a Banbury Mixer", Int. Polym.Proc. 1990, 5(3)178
[53] 吕柏源，赵嘉澍，仇卫星“热水循环温控装置在密炼机上使用效果的实验研究”，橡胶技术与装备，1989，2：22
[54] 蔡群英、张海，橡胶工业设计，1986，(2)，5～12
[55] 陈耀庭主编、北京化工大学等合编，橡胶加工工艺；1985，150
[56] 凌秋明，李宝和，侯国柱主编《橡胶生产过程计算机控制应用技术指南》，1993年3月，化工部科技司等编辑出版
[57] J. M. Funt著《Mixing of Rubbers》, Chap. 5, 1977, RAPRA Publications, Shawbury, U. K.
[2] James L. White"Development of Interal Mixer Technology of the Rubber Industry", Rubb. Chem. Tech., 1992, 65(3): 527, 刘安祥译，橡胶技术与装备，1994, 5: 11, 1994, 6: 23, 1995, 1: 13
[3] F. Kempter, German279, 649(1914)
[4] F. Kempter, German 280, 757 (1914)
[5] J. E. Pointon, U. S. 1, 138, 410(May4, 1915)
[6] F. H. Banbury(to Birmingham Iron Foundry), U. S. 1, 200, 070(Oct.3, 1916)
[7] 周彦豪编《聚合物加工流变学基础》，1988年3月，第1版，西安交通大学出版社
[8] 朝田充纪著“橡胶混炼机的新技术”，1987，3：35，李汉堂译，轮胎研究与开发，1989，2：46
[9] Dr. Samir Majumdar著, Rubb. News, 1996, 12: 29,姚琳译“密炼机混炼”，轮胎研究与开发，1997, 2: 37
[10] F. H. Banbury(to Birmingham Iron Foundry), U. S. 1, 512, 813 (Oct. 21, 1924)
[11] K. Frei, German 717, 687(1942)
[12] K. Frei, U. S. 2, 415, 091(Feb. 4, 1947)
[13] E. H, Ford (to Patterson Fowndry & Machine), U. S. 2, 559, 418(July 3, 1951)
[14] N. Sato, M. Miyaoko, S. Yamasaki, K. Inoue, A. Kuriyama, T. Fukui, T. Asia, K. Nakajimnd T. Maski((to Bridgestone Tire and Kobe Stell, Ltd.)U. S., 4, 284, 385 (Aug. 18, 1981)
[15] N. Sato, M. Miyaoko, S. Yamasaki, K. Inoue, A. Kuriyama, T. Fukai, and T. Asia(to Birdge-sone Tire and Kobe Steel), U. S. 4, 300, 838(Nov 17, 1981)
[16] K. Inoue, T. Fukia, T. Asia, Nakajima and A. Kurigama(to Kabushiki Kaishu Kobe Seibo Sho), U. S. 4, 456, 381(June26, 1984)
[17] N. O. Nortey(to Farrel Corporation), U. S. 4, 714, 350(Dec. 22, 1987)
[18] N. O. Nortey(to Farrel Corporation), U. S. 4, 744, 668(May 17, 1988)
[19] T. Asai and K. Hagiwara(to Rabushiki Kaishu Kobe Seiko Sho), U. S. 4, 718, 771(June 12, 1988)
[20] A. Kuriyama (to kabushiki Kaishu Kobe Seiko Sho), U. S. 4, 824, 259(April 25, 1989)
[21] G. C. Passoni (to Pomini Farrel S. P. A.), U. S. 4, 775, 240 (Oct.4, 1988)
[22] L. Pomini S. Crespi"Mixer with Variable Intermeshing Clearnce", Rubb. World, 1992, 4: 2
[23] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[24] 詹茂盛，纪冰，赵嘉澍等“销钉密炼室的混炼特性”，橡胶技术与装备，1988，1：18
[25] 赵嘉澍，汪传生，纪冰等“同步转子的试验研究”，橡胶技术与装备，1991，6：1
[26] 刘安祥，汪传生，赵嘉澍等“对同步转子密炼机混炼各种胶料的性能的研究”，橡胶技术与装备，1995，4：1
[27] 杨顺根“Pomini公司的密炼机及其新开发的HDM转子”，橡机工业，1995，4：11
[28] G. C. Passoni (to Pomini Farrel S. P. A.), U. S. 4, 775, 240 (Oct.4, 1988)
[29] L. Pomini S. Crespi"Mixer with Variable Intermeshing Clearnce", Rubb. World, 1992, 4: 2, 橡胶技术与装备, 1995, 4: 1
[30] 纪冰，胡海明，汪传生等“同速同向转子密炼机的研究”，合成橡胶工业，1997，4：207，CA，1997，9：644
[31] 唐国俊，李健宾(华南工学院)主编《橡胶机械设计》上册，1984年6月，第1版，化学工业出版社
[32] 陈国镇译“具有良好分散效果的MS型加压捏炼机”，橡胶技术与装备，1989，3：49(原文为日本《聚合物文摘》，1987，3)
[33] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[34] 赵嘉澍，詹茂盛，纪冰，蒋立达“密炼机转子改造的新型转子——销钉转子”，橡胶技术与装备，1987，1：19
[35] 方浩庭“密炼机销钉转子在生产中的应用”，橡胶技术与装备，1987，1：22
[36] 赵嘉澍，詹茂盛，李木松等“销钉转子的混炼功率”，橡胶工业，1988，2：95
[37] 詹茂盛，赵嘉澍，纪冰等“销钉密炼室的混炼功率和排胶温度”，橡胶技术与装备，1987，4：1
[38] 詹茂盛，赵嘉澍，纪冰等“销钉密炼室密炼机的试验研究”，特种橡胶制品，
[39] 赵嘉澍，李木松，詹茂盛，纪冰，蒋立达“转子构型对密炼机混炼过程的影响”，橡胶工业，1987，1：3
[40] 大连橡胶塑料机械研究编《橡胶塑料机械》，1986年9月，第1版，机械工业出版社
[41] 杨伟川“Guix-50U密炼机的简介”，橡胶技术与装备，1992，5：16
[42] 林宝善“国产密炼机的简要特征”，橡胶技术与装备，1992，5：56
[43] 阎锦涛“XM-270／20型密炼机曲拐式锁紧装置及其自锁角的计算”，橡胶技术与装备，1988，4：29
[44] 李纪新译“混炼过程的温度控制”，橡胶技术与装备，1985，2：24
[45] J. K. Kim and J. L. Whiter "An Experimental and Theoretical Study of Strvation Effects on Flow and Mixing Elastomers in an Internal Mixer", Nihon Reoroji Gakkaishi, 1989, 17(4): 203
[46] J. K. Kim, J. L. White, K. Min and W. Szydlowski "Simulation of Flow and Mixing in an Internal Mixer", Int. Polym. Proc., 1989, 44(1): 9
[47] J. L. White and J. K. Kim "Design Consideration for Internal Mixers: Mechanism of Motion of Elastomers in machines with Non-Intermeshing Rotors" , Kautsch. Gummi Kunstst. 1991, 44(3): 242
[48] K. Yagi and K. Kawanishi, Int. Polym. Proc., 1990, 5: 163
[49] 黄元昌译“英国法勒尔(Farrel)公司的Banbury密炼机”，橡胶工程信息，1999，10：13(原文英国《Farrel Banbury Mixer》，样本，1999．6)
[50] P. K. Freakley and W. Y. Wan Idris "Visualization of Flow During the Processing of Rubber in an Interal Mixer", Rubb. Chem. Tech. 1979, 52: 134
[51] J. J. Cheng and I. Manas-Zlocower"Hydrodynamic Analysis of a Banbury Mixer-2-D Flower Simulations for the Entire Mixing Champer", Polym. Eng. Sci., 1989, 29(5): 1059
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