Numerical Simulations of Polymer Melt Conveying in Co-Rotating Twin Screw Extruder

The 3 D non isothermal flow of non Newtonian viscous polymer melt in a co rotating twin screw extruder is modeled. The distributions of the velocity, temperature, pressure and the viscous dissipation in the flow domain are presented by using a fluid dynamics analysis package (Polyflow). The numerical results show that the temperatures are high in the intermeshing region and on the screw surface, the maximum pressure and the minimum pressure occur in the intermeshing region, and the flow rate is almost proportional to the screw speed.

Numerical study on mixing performance of screw elements in intermeshing counter-rotating and co-rotating twin-screw extrudes

The flow process of unplasticized polyvinyl chloride （U PVC） through the mixing zone of intermeshing counter rotating and co rotating twin screw extruders （TSEs） were numerically simula ted by the finite element method. Three dimensional isothermal flow field of U-PVC in two kinds of TSE was calculated. The mixing performance of the screw elements of the extruders was statistically analyzed by particle tracking method. The dispersive mixing performance was characterized by the mixing index, the logarithm of stretching, and the segregation scale. The distributive mixing per forulance was characterized by the resident time distribution. The results indicate that the counter rotating TSE can build higher pressure and generate higher axial velocity and shear rate, whereas the co rotating TSE has better performance in dispersive and distributive mixing.

Temperature and thermodynamic deformation analysis of the rotors on a twin screw multiphase pump with high gas volume fractions

The pressure increasing process within a twin screw multiphase pump, under the condition of high gas volume fractions (GVFs), induces large temperature and pressure changes that cause the rotors to deform. Rotor deformations heavily influence the backflow of the multiphase fluid through clearances within the twin screw multiphase pump and these deformations may even lead to pump failures. An accurate temperature and pressure distribution on the screw rotors need be obtained before the deformation analysis can be carried out. By means of small temperature and pressure sensors embedded into the groove at the root of the rotors, the temperatures of 12 points on the rotors and the pressure distributions of a twin screw multiphase pump under high GVFs conditions were recorded. Temperature test results were adopted to perform a heat transfer analysis for determining the temperature distribution on the screw rotors. Then deformation analyses, including thermal deformation, force deformation, and total deformation, were conducted according to the pressure and temperature distributions. Deformation analysis for different materials was also conducted under the same boundary conditions. A material was suggested for the manufacturing of rotors in a twin screw multiphase pump under the condition of high gas volume fractions.

GPU-enhanced DEM analysis of flow behaviour of irregularly shaped particles in a full-scale twin screw granulator

During twin screw granulation(TSG),small particles,which generally have irregular shapes,agglomerate together to form larger granules with improved properties.However,how particle shape impacts the conveying characteristics during TSG is not explored nor well understood.In this study,a graphic processor units(GPUs)enhanced discrete element method(DEM)is adopted to examine the effect of particle shape on the conveying characteristics in a full scale twin screw granulator for the first time.It is found that TSG with spherical particles has the smallest particle retention number,mean residence time,and power consumption;while for TSG with hexagonal prism(Hexp)shaped particles the largest particle retention number is obtained,and TSG with cubic particles requires the highest power consumption.Furthermore,spherical particles exhibit a flow pattern closer to an ideal plug flow,while cubic particles present a flow pattern approaching a perfect mixing.It is demonstrated that the GPU-enhanced DEM is capable of simulating the complex TSG process in a full-scale twin screw granulator with non-spherical particles.

Three-dimensional Modeling for Predicting the Vibration Modes of Twin Ball Screw Driving Table

As a redundant drive mechanism, twin ball screw feed system has the advantage of high stiffness and little yaw vibration in the feeding process, while leads to increased difficulty with vibration characteristics analysis and structure optimization. Only low-dimensional structure and dynamics parameters are considered in the existing research, the complete and effective model for predicting the table＇s vibrations is lacked. A three-dimensional（3D） mechanical model of twin ball screw driving table is proposed. In order to predict the vibration modes of the table quantitatively, an analytical formulation following a comprehensive approach is developed, where the drive system is modeled as a lumped mass-spring system, and the Lagrangian method is used to obtain the table＇s independent and coupled axial, yaw, and pitch vibration modes. The frequency variation of each mode is studied for different heights of the center of gravity, nut positions and table masses by numerical simulations. Modal experiment is carried out on the Z-axis feed table of the horizontal machining center MCH63. The results show that for each mode, the error between the estimated and the measured frequencies is less than 13%. The independent and coupled vibration modes are in accordance with the experimental results, respectively The proposed work can serve a better understanding of the table＇s dynamics and be beneficial for optimizing the structure parameters of twin ball screw drive system in the design stage.

Performance of Semi-solid Slurry Produced by Twin-screw Stirring Mixer and Rheo-diecasting Process of AZ91D Alloy

The microstructure of semi-solid slurry of AZ91D alloy, which was produced by twin-screw stirring mixer under the different parameters, was investigated.Rheoforming by cold chamber die casting process was performed thereafter. The results indicate that with decreasing of the barrel temperature of the mixer and the pouring temperature of molten Mg alloy, the solid fraction of semi-solid slurry increases and the size of non-dendritic grains becomes smaller. While the shear rate increases, the solid fraction of semi-solid slurry decreases. The tensile strength and elongation of metal rheoformed by die casting are higher by about 37% and 44% respectively than those produced by conventional liquid die casting.

Numerical Simulation of Twin-Screw Extrusion with Wall Slip

Wall slip boundary condition is first introduced into twin-screw extrusion with the Navier slip law. Three-dimensional isothermal flow in the twin-screw extruder is simulated by using the finite element package POLYFLOW. Profiles of velocity contours in the screw channel and shear rate distributions in the intermeshing region are presented for different slip coefficients. Curves of axial pressure difference, average shear rate and dispersive mixing index vs. the slip coefficient are plotted and discussed. Comparisons are also made between the wall slip conditions and the non-slip condition. The simulation results indicate that, as the level of wall slip decreases, the axial pressure difference rises, the shear effect is intensified and the axial mixing is also enhanced. All these flow characteristics seem to level off with the increase of the slip coefficient. However, because of the inherent limitation of the Navier slip law, use of an overestimated slip coefficient would predict an over-sticky state between the screw surface and the polymer melt.

Study on Hardware-in-loop Simulation of Twin-screw Extruder Experiment System

In order to facilitate the teaching of industrial processes and experiments on the twin-screw extruder control debugging,and be closer to the actual testing,to reduce the debugging costs and the risk of debugging process,the paper designs a hardware-in-loop simulation of twin-screw extruder experiment system which is closer to scene,low cost and high safety.The system through the establishment of twin-screw extruder’s mathematical model on computer to simulate the realistic system and there is hardware practicality in the computer simulation loop.The hardware based on C8051F020 can operate in the simulation loop in real time.In computer software design, we desigh man-machine interface that is intuitive and easy to operate,can reflect twin-screw extruder main operation information vividly.Finally,twin-screw extruder’s 3 heater temperature mathematical model and PID incremental control algorithm are presented.

HA/UHMWPE Nanocomposite Produced by Twin-screw Extrusion

The HA/UHMWPE nanocomposite is compounded by twin-screw extrusion of the HA and UHMWPE powder mixture in paraffin oil and then compression molded to a sheet form. TGA measurement shows the HA weight loss after processing is about 1%-2% . FTIR spectra indicate the paraaffin oil residue is trivial and UHMWPE is not oxidized. SEM reveals the HA nano particles are homogeneously dispersed by twin-screw extrusion and the inter-particle spaces are penetrated with UHMWPE fibrils by swelling treatment. HRTEM image indicates the HA particles and UHMWPE are intimately contacted by mechanical interlocking. Compared with the unfilled UHMWPE, stiffness of the composite with the HA volume fraction 0. 23 was significantly enhanced to 9 times without detriment of the yield strength and the ductility.

双螺杆压缩机工作性能测试实验平台搭建及教学应用

为提升“过程流体机械”实验教学的高阶性、创新性、挑战度,设计开发了双螺杆压缩机工作性能测试实验平台。该平台可实现工作性能测试、示功(p-V)图绘制等常规实验,并支持开展变工况调节特性分析以及啮合副型面优化设计验证等研究性实验。平台硬件部分根据啮合副型面特征设计了传感器布置方案;软件部分基于LabVIEW软件完成在变载工况下绘制p-V图、计算指示功率及分析效率等数据处理功能。该平台应用于实验教学可为培养学生的工程实践创新能力提供保障。

藜麦挤压面条加工工艺优化

以藜麦为原料,采用双螺杆挤压技术制备藜麦面条。以蒸煮特性和质构特性为考察指标,在单因素试验的基础上,应用响应面法优化挤压藜麦面条的挤压工艺参数,探究挤压温度、物料水分含量和螺杆转速对面条品质的影响。结果表明,挤压藜麦面条的最佳工艺条件为挤压温度113℃、物料水分含量45%、螺杆转速80r/min,此时面条的蒸煮损失较低,硬度较高。

阴阳转子型双螺杆结构的实验研究

为了设计出更加高效的双螺杆,提升挤出膨化机的工作效率;提出了一种引进阴阳转子的非对称双螺杆模型,基于螺旋式的螺杆模型,设计了阴阳转子型双螺杆,与传统双螺杆进行了仿真对比分析,并对新型双螺杆的准确性进行了实验验证;采用SolidWorks软件建模,利用ANSYS模拟流道数值,求得物料在机筒内的工作状态,分析阴阳转子型双螺杆的宏观压力、速度矢量和速度流线,并研究了不同转速对阴阳转子型双螺杆输送速度和挤出量的影响。研究结果表明:阴阳转子型双螺杆的宏观压力呈递增状态,速度矢量分布不均匀,速度流线混乱,能增加机筒内物料的传输速度,改变物料输送状态,提高物料挤出量。研究结果丰富了双螺杆的研究思路,为高效率挤出膨化机的设计与应用提供了理论依据。

工况对双螺杆混输泵振动特性影响实验

为研究工况对双螺杆混输泵振动特性的影响,搭建双螺杆混输泵多通道振动测试系统,测试并分析不同含气率、转速及出口压力下混输泵振动参数。结果表明:排液开始时排液腔瞬时打开诱发射流,射流向竖直向的泵出口偏转从而产生压力脉动并诱发振动,导致泵竖直方向振动加速度有效值高于水平方向和轴向;含气率为7.5%时振动加速度有效值为纯液工况时的1.88倍,随着含气率进一步升高测量值降低;而含气率大于20%时,振动有效值继续升高。在转速为1450r/min时y方向振动加速度有效值是850r/min时的2.95倍;振动加速度有效值随出口压力变化较小。当转速由850r/min升高至1450r/min时,径向垂直方向振动加速度主频由75fn移动至50fn。研究可为提高双螺杆混输泵运行稳定性提供指导。

基于苦荞的低GI高膳食纤维面条挤压工艺研究

本研究以挤出改性苦荞粉为基料,添加复合膳食纤维,研制低GI高膳食纤维面条,采用单因素和响应面试验优化面条的最佳工艺参数。结果表明:当螺杆转速22.36 Hz、水分添加量24.51%、挤出温度88.67℃时,以苦荞为基料的低GI高膳食纤维面条的感官评分最高为93.64分。对苦荞营养面条感官评分的影响因素从大到小为:螺杆转速>水分添加量>挤出温度。本研究利用苦荞低GI高膳食纤维的特性,采用双螺杆挤出技术开发出一款适合三高人群的产品。

阻燃永久抗静电型TPAE复合材料的制备

研究将聚酰胺弹性体(TPAE)、氮磷系阻燃剂和聚季铵盐永久抗静电剂,通过双螺杆挤出机进行共混、熔融、挤出,制备得到阻燃抗静电的TPAE复合材料,考察其导电、阻燃和力学性能。结果表明:随着抗静电剂的增加,TPAE材料的表面电阻率呈降低趋势;氮磷系阻燃剂可使TPAE材料的阻燃等级达到UL94-V0级。

双螺杆挤压双菇复合膨化食品的配方研究

以大米粉为主要原料,辅以杏鲍菇和香菇等辅料,采用双螺杆挤压技术,经过拌料、挤压膨化、切割、烘烤、调味等工艺研制双菇(香菇、杏鲍菇)复合膨化食品。在单因素的基础上,以感官评分和膨化度为综合考察指标,利用Box-Beheken响应面优化双菇复合膨化食品的配方。实验结果表明,双螺杆挤压工艺参数为:挤压温度Ⅰ区50℃、Ⅱ区130℃和Ⅲ区150℃,调整转速为230.00 r/min,在此工艺条件下制备双菇复合膨化食品的最优配方为:以大米粉为基础配方,香菇添加量为10%,杏鲍菇添加量为9%、罗汉果甜苷添加量为0.03%,此时综合评分最高,为94.16。在此条件下制备的双菇膨化食品,膨化效果最好,具有较好的色泽和香菇杏鲍菇特有的香气。

双螺杆挤出机胶粉脱硫工艺条件的研究

研究同向双螺杆挤出机的螺杆结构、脱硫温度和螺杆转速对胶粉脱硫的影响。结果表明:螺杆结构越有利于提高螺杆的混合和剪切能力,胶粉的溶胶含量越大,交联密度越小;当脱硫温度从170℃升高至190℃时,胶粉的脱硫效果有一定改善;当螺杆转速从50 r·min^(-1)增至90 r·min^(-1)时,胶粉的脱硫效果明显改善;当脱硫温度为180~190℃、螺杆转速为50~70 r·min^(-1)时,中等混合和剪切能力螺杆脱硫的胶粉的脱硫效果较好,脱硫胶粉胶料的拉伸性能较优。

活化胶粉复合改性沥青混合料的路用性能评价

为评价双螺杆活化胶粉复合SBS改性沥青及其混合料的低温性能,用测力延度、半圆弯曲和裂缝扩展性能试验分别测试了SBS改性沥青、未活化胶粉复合SBS改性沥青和双螺杆活化胶粉复合SBS改性沥青的低温性能指标,并采用熵权法对测力延度指标进行优选,通过荧光显微镜和四组分试验对3种沥青的性能变化进行机理分析.结果表明:测力延度指标中最大屈服点可有效表征双螺杆活化胶粉复合SBS改性沥青的低温性能;双螺杆活化过程中交联键被打开,并与SBS形成稳定的交联网络结构,显著提高了改性沥青混合料的高温性能和抗水损害性能.

啮合同向差速双螺杆挤出机挤出聚乳酸流场分析

目的:探究不同差速比的螺杆组在流道性能上的差异,明确差速对聚乳酸材料挤出性能的影响。方法:应用Solidworks软件建立4组差速双螺杆组,通过Fluent软件进行网格划分和有限元数值模拟,使用CFD-post软件分析计算结果,并对其性能进行验证。结果:当进出口压力分别为0.2,0.5 MPa,单头基准转速为30 r/min时,差速比为1∶2和1∶3的螺杆在不同性能下各有优劣,螺杆的产量和机筒内压力在差速比为1∶2时具有优势,螺杆的混合能力在差速比为1∶3时具有优势。结论:对比传统双螺杆挤出机,差速双螺杆挤出机对聚乳酸材料的挤出性能为正向影响,可作为全新的聚乳酸改性设备。

大豆分离蛋白、豌豆分离蛋白和小麦面筋蛋白相互作用对高水分植物蛋白肉品质特性的影响

混合多种蛋白原料以创造具有所有原料特征的人造肉产品已经在食品领域得到研究。然而,在高水分植物蛋白肉生产领域暂未得到研究,目前也没有对使用大豆分离蛋白(SPI)、豌豆分离蛋白(PPI)和小麦面筋蛋白(WGP)的混合原料开发植物蛋白肉的研究。该研究的目的是减少植物蛋白肉生产的经济成本,考察由SPI、PPI和WGP共混制备的植物蛋白肉是否比仅用SPI和PPI、SPI和WGP制备的植物蛋白肉具有更好的品质特性以及考察SPI、PPI和WGP以不同比例混合时蛋白之间的相互作用对高水分植物蛋白肉品质特性的影响。研究结果表明,WGP占比的增加增大了产品的硬度和咀嚼性,所有的混合原料基样品均呈现很好的组织化结构,当样品配比为P20W30时达到了最高的组织化度(2.14±0.07),混合蛋白原料也使产品的持水率增加,表观观察和SEM也显示3种混合蛋白原料产品有着更好的拉丝效果和纤维化结构,此外,傅里叶变换红外光谱表明混合蛋白原料产品主要以稳定的β结构存在,WGP占比的增加降低了产品的流变性能。总的来说,该研究表明混合3种蛋白制备的植物蛋白肉有着更好的品质特性。