双螺杆挤出熔融理论的可视化研究
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摘要
双螺杆挤出中的熔融是理论研究的薄弱点之一,其主要原因是在相当长的一段时间内人们对熔融现象无法作直接的观察。本文作者利用所在的北京化工大学塑料机械及塑料工程研究所自行研制的三向全程可视化双螺杆挤出机进行实验观察,描述并分析了同向双螺杆挤出的固体输送和熔融现象,在此基础上对熔融过程作了较深入的理论研究,提出了一些新的学术观点与理论。
     本文的主要观点和工作结果如下:
     (1) 提出同向双螺杆挤出的熔融过程中物料运动具有多种形式的观点。造成物料运动多样性的根本原因是双螺杆复杂的几何关系和运动关系导致正常挤出时大部分螺槽的非充满,加料量因而成为一个独立的工艺操作变量。本文初步总结了在熔融阶段几种常见的运动形式,并把它们分为连续的和非连续的两大类。有了运动形式多样性的思想,在实际生产中,可以通过控制设备参数(如螺杆组合)、加工条件(如加料量)等方法使物料以预计的形式运动;在理论研究中,则指出应针对不同的运动形式建立不同的物理与数学模型。
     (2) 分析了与熔融有着密切关系的固体输送现象,提出了固体输送的两区物理模型。物料自加料口加入机筒即进入散粒体区,在此区域中,物料几乎作完全的正位移运动,重力在这一过程中起了重要的作用。随着温度的升高,物料与螺杆间、料粒之间开始有轻微的粘连而形成环流,此区域被称为粘连区,固体物料形成环流是粘连区的特点。
     (3) 通过实验观察,发现在同向双螺杆挤出的熔融阶段,未熔物料(无论是粒料还是粉料)始终散布在熔料(熔体)中。这是因为物料在通过啮合区时受到挤压、阻挡,啮合区对固、液两相产生物理掺混的作用。在双螺杆挤出的熔融段,没有一个明显的固、液相间的分界面,这是与单螺杆挤出现象的不同之处。
     (4) 物料的连续型运动形式出现于较大加料量时,这意味着可以获得较大的挤出产量。本文就熔融段中物料的两种连续型运动形式,根据能量方程和运动方程分别建立平动模型和平动滚动模型,并作了数学求解和理论计算,最
The study on polymer's melting in twin-screw extrusion has been one of difficulties in theory researches, mainly because we couldn't observe the melting phenomena directly. With the three-dimension successive windowed twin-screw extruder, which is developped by the Institute of Plastics Machinery and Engineering, Beijing University of Chemical Technology, the author carrys on several extrusion experiments. In this thesis the solid conveying and melting phenomena of twin screw extrusion are observed, described and analized. Melting process is studied theoretically,and several new ideas are presented. Main study results are as follows :
    1. There are several flow patterns at melting section in co-rotating twin screw extrusion. This is caused mainly by the complex geometry and motion relations of the twin screw, and thus feeding rate is independent. Flow patterns in melting section are classified into two types, continuous and uncontinuous. With the idea of manifold flow patterns, we can try to let polymer flowing in planned pattern by means of controlling screw configuration and processing conditions, feeding rate, for instance. When we do theory research, the idea let us understand that we should establish different physical and mathematical models for different flow patterns.
    2. The phenomena of solid conveying are analized and solid conveying physical model — two region model — is established. In the first region, we call it dispersed
    solid region, polymer moves at almost entire positive displacement, and gravity plays an important role here. In the second region polymer pellets adhere to the screw and other pellets slightly, and move round along the " 8 " -shaped channel. This region
    is called adhesive solid region.
    3. We observe that the solid pellets (powder consists of small pellets also) which haven't melted always distribute in melt, because of the intermeshing zone's physical
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