聚合物复合材料三螺杆动态挤出过程及其结构性能研究
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摘要
聚合物复合材料已广泛应用于航空航天、汽车、电子电气、建筑、医疗器械、家电、包装等领域，近年市场需求量不断增加。然而当前制备聚合物复合材料的技术及设备主要是单螺杆混炼挤出机、双螺杆混炼挤出机，这些传统设备存在混合分散效果差，能耗高，挤出制品质量低等问题。我们提出并发明了中间螺杆可振动的一字排列三螺杆混炼挤出方法及技术，为聚合物复合材料的制备与加工提供了新的手段，对聚合物复合材料的应用与发展具有十分重要的科学与现实意义。
通过三螺杆动力传动分配、电磁激振力与挤压系统机械结构的协同作用，实现了通过中间螺杆轴向振动使主螺杆和两侧副螺杆间的轴向啮合间隙发生周期性变化，将振动力场引入聚合物复合材料塑化混炼全过程，并成功研制了一字排列三螺杆动态混炼挤出机；建立了中间螺杆轴向振动动力学模型和分析中间螺杆轴在阻尼系统中的幅频特性，并利用Tanner修正的Maxwell非线性本构方程对三螺杆螺槽C型室内物料的流动进行了三维数值模拟，证明了中间螺杆的轴向振动对聚合物复合材料的混炼挤出过程特性产生了深刻的影响，发现了振动力场导致螺槽C型室内物料产生混沌混合现象，同时提出和定义了一个无因次组合数（准数VI1）作为振动力场强化物料分布混合的指标。
通过建立中间螺杆可振动三螺杆挤压系统的物理模型及数学模型，采用网格重叠技术，数值模拟和分析了三螺杆螺槽内熔体速度、压力、粘度、剪切速率等与螺杆转速、中间螺杆振频或振幅等参数的关系，发现随转速、振频、振幅的增加，流场的剪切速率、速度、流量、螺棱两侧压差等都有一定程度的增加，而流场的粘度均值、压力均值都有一定程度的下降，并且流道内的压力、剪切速率等呈周期性变化，由此推断三螺杆动态挤出机的剪切混合作用随转速、振动强度的增加而增强，证明了中间螺杆振动强化了聚合物复合材料的混合混炼过程，从而能提高聚合物复合材料制品性能。
利用我们自行研制的一字排列三螺杆动态混炼挤出机分别加工与制备了三元乙丙橡胶/聚丙烯、硅灰石/聚丙烯、超细碳酸钙/聚丙烯这三种比较典型的聚合物复合材料。通过改变中间螺杆的振动参数（振频和振幅）、三螺杆转速和复合体系组成比率等参数，重点研究了复合材料制品的拉伸强度、冲击强度、断裂伸长率、相态结构与振动参数之间的关系，发现了与稳态（没有引入振动力场）相比较动态（引入振动力场）加工条件下复合材料制品力学性能得到不同程度提高，其微观结构得到了很大改善等规律，证明了中间螺杆可振动的一字排列三螺杆混炼挤出方法及技术能够改善与提高聚合物复合材料制品的结构性能，也说明了一字排列三螺杆动态混炼挤出机非常适合加工与制备聚合物复合材料。
Polymer composites have been widely used in different fields such as aerospace,automotive, electronics, electrical, construction, medical equipment, home appliances, andpackaging, and the market demand for it is increasing in recent years. However, thepreparation equipments of polymer composites are mainly single-screw or twin screwcompounding extruders, these traditional devices have a number of disadvantages: poordispersion, high energy consumption and low product quality. We propose and invent thatline-shape arranged three-screw extrusion mixing methods and techniques with a vibratilemiddle screw, which provides a new means for the preparation and processing of polymercomposites, and it has very important scientific and practical significance on the applicationand development of polymer composites.
Through the synergies between the distribution of tri-screw power transmission,electromagnetic exciting force and the extrusion system mechanical structure, the axialmeshing gap between the main screw and both sides of the vice screw changed periodicallythrough axial vibration of the middle the screw, and the vibration force field was brought intothe whole mixing and plasticizing process of polymer composites, and the line-shape arrangedthree-screw dynamic mixing extrusion was successfully developed. In this paper, axialvibration dynamic model of the middle screw was established and its amplitude-frequencycharacteristics in the damping system were analyzed. Trough Tanner’s amendment Maxwellnonlinear constitutive equation, a three-dimensional numerical simulation of flow ofthree-screw C-type groove indoor materials was accomplished, which proved that axialvibration of the middle screw takes profound effect on melt mixing and process of extruding,and found that the vibration force field led the C-type groove indoor materials to producechaotic mixing phenomenon, proposed and defined a dimensionless combinatorial number(quasi-number VI1) as an index to indicate the extent of strengthening mixing and dispersionof materials by the vibration force field.
In this paper, we established physical and mathematical model of three-screw extruderwith a vibratile middle screw. By using overlapping grid technique, we simulated andanalyzed the relationship between melt velocity, pressure, viscidity and shearing velocity andscrew speed, the middle screw vibration frequency or amplitude. The results showed that theflux, velocity, shearing velocity increased with the increasing of the screw speed, vibrationamplitude and vibration frequency. However, the average viscidity, pressure decreased atsome degree. And the pressure inside the flow channel and the shear rate varies periodically. Obviously, mixing function was improved when increasing the screw speed, vibrationamplitude and vibration frequency. This proved that the vibration of the middle screw couldstrengthen the mixing process and enhance the product performance of polymer composites.
Using self-developed line-shape arranged tri-screw dynamic mixing extruder, weprepared EPDM/PP, wollastonite/polypropylene and ultra-fine calciumcarbonate/polypropylene three typical polymer composites. The experiments which changethe vibration parameters (vibration frequency and amplitude), screw speed and filling ratiofocused on the inherent law between the tensile strength, impact strength, fracture elongation,phase structure with vibration parameters. Results showed that comparing with steady state(without the vibration force field), the mechanics properties of composites produced byvibration extrusion were improved at different degree and the material had excellentmicrostructure. Meanwhile, the results verified the introduction of vibration to the middlescrew could improve the structural behavior and quality of composites and the machine isideal for the processing and preparation of polymer composites.
通过三螺杆动力传动分配、电磁激振力与挤压系统机械结构的协同作用，实现了通过中间螺杆轴向振动使主螺杆和两侧副螺杆间的轴向啮合间隙发生周期性变化，将振动力场引入聚合物复合材料塑化混炼全过程，并成功研制了一字排列三螺杆动态混炼挤出机；建立了中间螺杆轴向振动动力学模型和分析中间螺杆轴在阻尼系统中的幅频特性，并利用Tanner修正的Maxwell非线性本构方程对三螺杆螺槽C型室内物料的流动进行了三维数值模拟，证明了中间螺杆的轴向振动对聚合物复合材料的混炼挤出过程特性产生了深刻的影响，发现了振动力场导致螺槽C型室内物料产生混沌混合现象，同时提出和定义了一个无因次组合数（准数VI1）作为振动力场强化物料分布混合的指标。
通过建立中间螺杆可振动三螺杆挤压系统的物理模型及数学模型，采用网格重叠技术，数值模拟和分析了三螺杆螺槽内熔体速度、压力、粘度、剪切速率等与螺杆转速、中间螺杆振频或振幅等参数的关系，发现随转速、振频、振幅的增加，流场的剪切速率、速度、流量、螺棱两侧压差等都有一定程度的增加，而流场的粘度均值、压力均值都有一定程度的下降，并且流道内的压力、剪切速率等呈周期性变化，由此推断三螺杆动态挤出机的剪切混合作用随转速、振动强度的增加而增强，证明了中间螺杆振动强化了聚合物复合材料的混合混炼过程，从而能提高聚合物复合材料制品性能。
利用我们自行研制的一字排列三螺杆动态混炼挤出机分别加工与制备了三元乙丙橡胶/聚丙烯、硅灰石/聚丙烯、超细碳酸钙/聚丙烯这三种比较典型的聚合物复合材料。通过改变中间螺杆的振动参数（振频和振幅）、三螺杆转速和复合体系组成比率等参数，重点研究了复合材料制品的拉伸强度、冲击强度、断裂伸长率、相态结构与振动参数之间的关系，发现了与稳态（没有引入振动力场）相比较动态（引入振动力场）加工条件下复合材料制品力学性能得到不同程度提高，其微观结构得到了很大改善等规律，证明了中间螺杆可振动的一字排列三螺杆混炼挤出方法及技术能够改善与提高聚合物复合材料制品的结构性能，也说明了一字排列三螺杆动态混炼挤出机非常适合加工与制备聚合物复合材料。
Polymer composites have been widely used in different fields such as aerospace,automotive, electronics, electrical, construction, medical equipment, home appliances, andpackaging, and the market demand for it is increasing in recent years. However, thepreparation equipments of polymer composites are mainly single-screw or twin screwcompounding extruders, these traditional devices have a number of disadvantages: poordispersion, high energy consumption and low product quality. We propose and invent thatline-shape arranged three-screw extrusion mixing methods and techniques with a vibratilemiddle screw, which provides a new means for the preparation and processing of polymercomposites, and it has very important scientific and practical significance on the applicationand development of polymer composites.
Through the synergies between the distribution of tri-screw power transmission,electromagnetic exciting force and the extrusion system mechanical structure, the axialmeshing gap between the main screw and both sides of the vice screw changed periodicallythrough axial vibration of the middle the screw, and the vibration force field was brought intothe whole mixing and plasticizing process of polymer composites, and the line-shape arrangedthree-screw dynamic mixing extrusion was successfully developed. In this paper, axialvibration dynamic model of the middle screw was established and its amplitude-frequencycharacteristics in the damping system were analyzed. Trough Tanner’s amendment Maxwellnonlinear constitutive equation, a three-dimensional numerical simulation of flow ofthree-screw C-type groove indoor materials was accomplished, which proved that axialvibration of the middle screw takes profound effect on melt mixing and process of extruding,and found that the vibration force field led the C-type groove indoor materials to producechaotic mixing phenomenon, proposed and defined a dimensionless combinatorial number(quasi-number VI1) as an index to indicate the extent of strengthening mixing and dispersionof materials by the vibration force field.
In this paper, we established physical and mathematical model of three-screw extruderwith a vibratile middle screw. By using overlapping grid technique, we simulated andanalyzed the relationship between melt velocity, pressure, viscidity and shearing velocity andscrew speed, the middle screw vibration frequency or amplitude. The results showed that theflux, velocity, shearing velocity increased with the increasing of the screw speed, vibrationamplitude and vibration frequency. However, the average viscidity, pressure decreased atsome degree. And the pressure inside the flow channel and the shear rate varies periodically. Obviously, mixing function was improved when increasing the screw speed, vibrationamplitude and vibration frequency. This proved that the vibration of the middle screw couldstrengthen the mixing process and enhance the product performance of polymer composites.
Using self-developed line-shape arranged tri-screw dynamic mixing extruder, weprepared EPDM/PP, wollastonite/polypropylene and ultra-fine calciumcarbonate/polypropylene three typical polymer composites. The experiments which changethe vibration parameters (vibration frequency and amplitude), screw speed and filling ratiofocused on the inherent law between the tensile strength, impact strength, fracture elongation,phase structure with vibration parameters. Results showed that comparing with steady state(without the vibration force field), the mechanics properties of composites produced byvibration extrusion were improved at different degree and the material had excellentmicrostructure. Meanwhile, the results verified the introduction of vibration to the middlescrew could improve the structural behavior and quality of composites and the machine isideal for the processing and preparation of polymer composites.
引文
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