注塑螺杆构型对塑化能耗影响的研究
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摘要
近年来,能源问题越来越多地受到人们重视,节能降耗也成为政府评价企业优良的主要指标。而随着注塑机的不断改进发展,注塑机的能耗问题也日趋凸现出来。如何提高注塑机性能,开发节能型注塑机,成为生产企业提高市场竞争力的主要因素。
本文主要研究了注塑螺杆参数变化对塑化单产能耗的影响。
本文对注塑螺杆计量段长度L_3(螺杆长径比)、螺距S、槽深h_3(螺杆压缩比)及螺棱顶部距机筒内壁间隙δ四个因素建立正交试验表,通过ProE软件建立螺杆计量段模型,用Gambit进行螺杆和流道的有限元网格划分,通过流体有限元分析软件POLYFLOW模拟分析了它们对注射机塑化单产能耗的影响。
建立注塑成型机实验台测试系统,对注射成型机塑化能耗进行测量。通过加装传感器,对注塑机螺杆转矩、功率和转速以及电机功率进行实时在线测量。
设计加工模拟的9根螺杆,对螺杆参数变化与注塑机塑化单产能耗关系进行了实验研究。结合实验结果,运用正交实验表通过极差分析、综合比较找出计量段长度L_3(螺杆长径比)、螺距S、槽深h_3(螺杆压缩比)及螺棱顶部距机筒内壁间隙δ对塑化单产能耗影响的大小,同时结合螺杆的混合性能,与模拟结果综合比较,最后给出了在混合性能最优情况下能耗最低的螺杆参数,为实际生产中设计节能型螺杆提供了参考,对实际生产有一定的指导意义。
In recent years, more and more energy problems cause people's attention, the energy consumption has also become the key indicators the government evaluates the enterprises whether they are excellent or not. With the continuous improvement of injection molding machines, the energy problems are becoming increasingly emerged. How to improve the performance of injection molding machines and develop energy-saving injection molding machines become the main factors for the production enterprises to improve the market competitiveness.
This paper studied the effect of screw parameters on plastizing uniproducing energy consumption of injection molding machine.
The orthogonal test was established for the slot depth h_3, length L_3, screw distance S of injection screw measurement segment and the apertureδ between screw and barrel inner-wall. By using the software ProE established the screw models, then division into finite element mesh by Gambit. And last through well know fluid element analysis software POLYFLOW, analyzed the effect of these four factors on plasting energy consumption.
Established the testing system for injection molding machine. Measure the screw torque and motor power on-line throw the installed sensors.
Then designed and processed the nine simulation screws, then studied their effect throw experiment. With the experimental result, using the orthogonal test identified the order of the factors, including depth h_3, length L_3, screw distance S of injection screw measurement segment and the apertureδ, on plasting energy consumption. Finally, combined with the mixing ability and simulation result we got the optimal screw parameters. For designing and producing the energy-saving screw, the result provides a reference.
本文主要研究了注塑螺杆参数变化对塑化单产能耗的影响。
本文对注塑螺杆计量段长度L_3(螺杆长径比)、螺距S、槽深h_3(螺杆压缩比)及螺棱顶部距机筒内壁间隙δ四个因素建立正交试验表,通过ProE软件建立螺杆计量段模型,用Gambit进行螺杆和流道的有限元网格划分,通过流体有限元分析软件POLYFLOW模拟分析了它们对注射机塑化单产能耗的影响。
建立注塑成型机实验台测试系统,对注射成型机塑化能耗进行测量。通过加装传感器,对注塑机螺杆转矩、功率和转速以及电机功率进行实时在线测量。
设计加工模拟的9根螺杆,对螺杆参数变化与注塑机塑化单产能耗关系进行了实验研究。结合实验结果,运用正交实验表通过极差分析、综合比较找出计量段长度L_3(螺杆长径比)、螺距S、槽深h_3(螺杆压缩比)及螺棱顶部距机筒内壁间隙δ对塑化单产能耗影响的大小,同时结合螺杆的混合性能,与模拟结果综合比较,最后给出了在混合性能最优情况下能耗最低的螺杆参数,为实际生产中设计节能型螺杆提供了参考,对实际生产有一定的指导意义。
In recent years, more and more energy problems cause people's attention, the energy consumption has also become the key indicators the government evaluates the enterprises whether they are excellent or not. With the continuous improvement of injection molding machines, the energy problems are becoming increasingly emerged. How to improve the performance of injection molding machines and develop energy-saving injection molding machines become the main factors for the production enterprises to improve the market competitiveness.
This paper studied the effect of screw parameters on plastizing uniproducing energy consumption of injection molding machine.
The orthogonal test was established for the slot depth h_3, length L_3, screw distance S of injection screw measurement segment and the apertureδ between screw and barrel inner-wall. By using the software ProE established the screw models, then division into finite element mesh by Gambit. And last through well know fluid element analysis software POLYFLOW, analyzed the effect of these four factors on plasting energy consumption.
Established the testing system for injection molding machine. Measure the screw torque and motor power on-line throw the installed sensors.
Then designed and processed the nine simulation screws, then studied their effect throw experiment. With the experimental result, using the orthogonal test identified the order of the factors, including depth h_3, length L_3, screw distance S of injection screw measurement segment and the apertureδ, on plasting energy consumption. Finally, combined with the mixing ability and simulation result we got the optimal screw parameters. For designing and producing the energy-saving screw, the result provides a reference.
引文
[1]K.R.Sheets.U.S.News & World Report[N],1986
[2]张友根.我国注塑机的特点及发展方向[J].塑料机械,2003
[3]王兴天.注塑技术与注射机[M].北京:化学工业出版社,2005.
[4]Oana R.Dumitrescu*,Dave C.Baker,Gary M.Foster,Ken E.Evans.Near infrared spectroscopy for in-line monitoring during injection moulding[C].School of Engineering,Computer Science and Mathematics,University of Exeter,North Park Road,Exeter,Devon EX4 4QF,UK
[5]瞿金平.塑料工业手册[M].第1版,化学工业出版社,2001.1-321
[6]F.Johannaber.Injection Molding Machines-a users guide[J].Oxford University Press,1985
[7]许政仓.我国塑料机械制造工业概况及展望[J].工程塑料应用,第30卷,第7期,2002
[8]王向东等.注射成型技术进展[J].中国塑料,第15卷,第十期,2001
[9]廖正品等.美国2000塑料橡胶工业博览会回顾(2)[J].中国塑料,14(10),2000
[10]李倩.塑料注射成型技术及其进展[J].中国塑料,2001(10),7-13
[11]王志新.现代注射机控制[M].第1版,北京:中国轻工业出版社,2001.1-2
[12]王兴天.注射成型技术[M].北京:化学工业出版社,1989
[13]F.约翰纳伯.注射成型机使用指南[M].北京:化学工业出版社,2004
[14]张友根.注射塑化系统设计研究[J].机械与模具,2006
[15]注射成型技术:2001现状与进展[J].国外塑料,2002
[16]朱复华.螺杆设计及理论基础[M].北京:化学工业出版社,1984
[17]Timothy W.Womer,Basic Screw Geometry.Elsevier
[18]北京化工学院,华南工学院.塑料机械设计[M].第一版,甘肃:轻工业出版社,1983.369
[19]王鸳鸯,黄明福,陈晋南.注塑螺杆研究进展[J].广东化工,第3期,第34卷,2007
[20]Paul Gramann,Chris Rauwendaal.New Dispersive and Distributive Mixers for Extrusion and Injection Molding.Elsevier
[21]刘际译.注射成型机用新型螺杆[J],塑料,2003,(2),91
[22]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,2001,15(1)
[23]张友根.注射螺杆与注射节能[J].广东塑料,第126期,2005,5-10
[24]张友根.注射塑化系统设计研究[J].机械与模具,2006,35-39
[25]张治华.塑料成型机单螺杆的改进[J].塑料加工应用,1996,(4),26-29
[26]中国能源发展报告[R],2006
[27]节能型直流驱动注射机[J].国外塑料,第3期,2003
[28]黄娜斌,姜波.各种节能技术在注射机上的应用[J].橡胶技术与装备,2007
[29]张友根.注射螺杆与注射节能[J].第126期,2005
[30]瞿金平.聚合物动态塑化成型加工[M].科学出版社,2002
[31]黄步明.注射机液压系统存在的主要问题及解决办法[J].广东塑料,2005
[32]张友根.我国注塑机的特点及发展方向[J].上海塑料,2004,4-9
[33]王兴天.国内注塑机的发展概述[J].塑料科技,第2期,2000
[34]世界五大塑料生产国产能状况[N].中国工业设备网,2006
[35]张友根.注塑机节能技术的分析研究[N].中国工业设备网,2007
[36]刘海滨.节能技术在注塑机中的应用[J].液压与气动,第6期,2007,56-59
[37]罗河胜.塑料工艺与实用配方[M].广东科技出版社,2005
[38]王华山.塑料注塑技术与实例[M].北京:化学工业出版社,2006
[39]Chris Rauwendaal,Paul Gramann,Bruce Davis,EXPERIMENTAL STUDY OF A NEW DISPERSIVE MIXER.Elsevier
[40]Chris Rauwendaal,Paul Gramann,Bruce Davis.NEW DISPERSIVE MIXERS FOR SINGLE SCREW EXTRUDERS.Elsevier
[41]Chris Rauwendaal.NON-RETURN VALVE WITH DISTRIBUTIVE AND DISPERSIVE MIXING CAPABILITY.Elsevier
[42]Antoine C Rios,Paul J Gramann,Ephraim Stanfield and Tim A.COMPARATIVE STUDY OF RHOMBOIDAL DISTRIBUTIVE MIXING SECTIONS USING COMPUTER MODELING.Elsevier
[43]A.B.Glanvill.塑料工程手册[M].轻工业出版社,1983
[44]J-L-怀特等.螺杆挤出[M].北京:化学工业出版社,2005
[45]张友根.注射螺杆技术进展和设计研究[J].塑胶工业,2007,8-11
[46]塑料机械设计[M].北京:轻工业出版社,2002
[47]栾军.现代实验设计的技术与方法[M].上海:上海交通大学出版社,1995
[48]正交实验设计方法.国防工业出版社,1976
[49]郑少华.实验设计与数据处理[M].中国建材出版社,2004
[50]Tuncay Erzurumlu,Babur Ozcelik,Minimization of warpage and sink index in injection-molded thermoplastic parts using Taguchi optimization method[J],Materials and Design,2006(27),853-861
[51]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 andDesign,2007(28),1271-1278
[52]Ming-Chih Huang,Ching-Chih Tai,The effective factors in the warpage problem of an injection-molded part with a thin shell feature[J],Journal of Materials Processing Technology,Vol.110,Issue 1,1 March 2001,1-9
[53]北京大学数学力学系数学专业.正交设计[M].1976
[54]张勤星.注塑成型工艺优化及制品重量控制[D].郑州大学,2005
[55]高欣.开槽注射螺杆计量段螺纹元件的混合机理研究[D].北京化工大学,2006
[56]POLYFLOW3.10 Documentation
[57]Raman V.Chiruvella,Y.Jaluria and A.H.Abib.Numerical Simulation of Fluid Flow and Heat Transfer in a Single-Screw Extruder with Different Dies.Polym.Eng.Sci.,V35,P261(MID-FEBRUARY 1995)
[2]张友根.我国注塑机的特点及发展方向[J].塑料机械,2003
[3]王兴天.注塑技术与注射机[M].北京:化学工业出版社,2005.
[4]Oana R.Dumitrescu*,Dave C.Baker,Gary M.Foster,Ken E.Evans.Near infrared spectroscopy for in-line monitoring during injection moulding[C].School of Engineering,Computer Science and Mathematics,University of Exeter,North Park Road,Exeter,Devon EX4 4QF,UK
[5]瞿金平.塑料工业手册[M].第1版,化学工业出版社,2001.1-321
[6]F.Johannaber.Injection Molding Machines-a users guide[J].Oxford University Press,1985
[7]许政仓.我国塑料机械制造工业概况及展望[J].工程塑料应用,第30卷,第7期,2002
[8]王向东等.注射成型技术进展[J].中国塑料,第15卷,第十期,2001
[9]廖正品等.美国2000塑料橡胶工业博览会回顾(2)[J].中国塑料,14(10),2000
[10]李倩.塑料注射成型技术及其进展[J].中国塑料,2001(10),7-13
[11]王志新.现代注射机控制[M].第1版,北京:中国轻工业出版社,2001.1-2
[12]王兴天.注射成型技术[M].北京:化学工业出版社,1989
[13]F.约翰纳伯.注射成型机使用指南[M].北京:化学工业出版社,2004
[14]张友根.注射塑化系统设计研究[J].机械与模具,2006
[15]注射成型技术:2001现状与进展[J].国外塑料,2002
[16]朱复华.螺杆设计及理论基础[M].北京:化学工业出版社,1984
[17]Timothy W.Womer,Basic Screw Geometry.Elsevier
[18]北京化工学院,华南工学院.塑料机械设计[M].第一版,甘肃:轻工业出版社,1983.369
[19]王鸳鸯,黄明福,陈晋南.注塑螺杆研究进展[J].广东化工,第3期,第34卷,2007
[20]Paul Gramann,Chris Rauwendaal.New Dispersive and Distributive Mixers for Extrusion and Injection Molding.Elsevier
[21]刘际译.注射成型机用新型螺杆[J],塑料,2003,(2),91
[22]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,2001,15(1)
[23]张友根.注射螺杆与注射节能[J].广东塑料,第126期,2005,5-10
[24]张友根.注射塑化系统设计研究[J].机械与模具,2006,35-39
[25]张治华.塑料成型机单螺杆的改进[J].塑料加工应用,1996,(4),26-29
[26]中国能源发展报告[R],2006
[27]节能型直流驱动注射机[J].国外塑料,第3期,2003
[28]黄娜斌,姜波.各种节能技术在注射机上的应用[J].橡胶技术与装备,2007
[29]张友根.注射螺杆与注射节能[J].第126期,2005
[30]瞿金平.聚合物动态塑化成型加工[M].科学出版社,2002
[31]黄步明.注射机液压系统存在的主要问题及解决办法[J].广东塑料,2005
[32]张友根.我国注塑机的特点及发展方向[J].上海塑料,2004,4-9
[33]王兴天.国内注塑机的发展概述[J].塑料科技,第2期,2000
[34]世界五大塑料生产国产能状况[N].中国工业设备网,2006
[35]张友根.注塑机节能技术的分析研究[N].中国工业设备网,2007
[36]刘海滨.节能技术在注塑机中的应用[J].液压与气动,第6期,2007,56-59
[37]罗河胜.塑料工艺与实用配方[M].广东科技出版社,2005
[38]王华山.塑料注塑技术与实例[M].北京:化学工业出版社,2006
[39]Chris Rauwendaal,Paul Gramann,Bruce Davis,EXPERIMENTAL STUDY OF A NEW DISPERSIVE MIXER.Elsevier
[40]Chris Rauwendaal,Paul Gramann,Bruce Davis.NEW DISPERSIVE MIXERS FOR SINGLE SCREW EXTRUDERS.Elsevier
[41]Chris Rauwendaal.NON-RETURN VALVE WITH DISTRIBUTIVE AND DISPERSIVE MIXING CAPABILITY.Elsevier
[42]Antoine C Rios,Paul J Gramann,Ephraim Stanfield and Tim A.COMPARATIVE STUDY OF RHOMBOIDAL DISTRIBUTIVE MIXING SECTIONS USING COMPUTER MODELING.Elsevier
[43]A.B.Glanvill.塑料工程手册[M].轻工业出版社,1983
[44]J-L-怀特等.螺杆挤出[M].北京:化学工业出版社,2005
[45]张友根.注射螺杆技术进展和设计研究[J].塑胶工业,2007,8-11
[46]塑料机械设计[M].北京:轻工业出版社,2002
[47]栾军.现代实验设计的技术与方法[M].上海:上海交通大学出版社,1995
[48]正交实验设计方法.国防工业出版社,1976
[49]郑少华.实验设计与数据处理[M].中国建材出版社,2004
[50]Tuncay Erzurumlu,Babur Ozcelik,Minimization of warpage and sink index in injection-molded thermoplastic parts using Taguchi optimization method[J],Materials and Design,2006(27),853-861
[51]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 andDesign,2007(28),1271-1278
[52]Ming-Chih Huang,Ching-Chih Tai,The effective factors in the warpage problem of an injection-molded part with a thin shell feature[J],Journal of Materials Processing Technology,Vol.110,Issue 1,1 March 2001,1-9
[53]北京大学数学力学系数学专业.正交设计[M].1976
[54]张勤星.注塑成型工艺优化及制品重量控制[D].郑州大学,2005
[55]高欣.开槽注射螺杆计量段螺纹元件的混合机理研究[D].北京化工大学,2006
[56]POLYFLOW3.10 Documentation
[57]Raman V.Chiruvella,Y.Jaluria and A.H.Abib.Numerical Simulation of Fluid Flow and Heat Transfer in a Single-Screw Extruder with Different Dies.Polym.Eng.Sci.,V35,P261(MID-FEBRUARY 1995)