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.

CONSTITUTIVE EQUATION OF CO-ROTATIONAL DERIVATIVE TYPE FOR ANISOTROPIC-VISCOELASTIC FLUID

A constitutive equation theory of Oldroyd fluid B type,i.e.the co-rotational derivative type,is developed for the anisotropic-viscoelastic fluid of liquid crystalline(LC)polymer.Analyzing the influence of the orientational motion on the material behavior and neglecting the influence,the constitutive equation is applied to a simple case for the hydrodynamic motion when the orientational contribution is neglected in it and the anisotropic relaxation,retardation times and anisotropic viscosi- ties are introduced to describe the macroscopic behavior of the anisotropic LC polymer fluid.Using the equation for the shear flow of LC polymer fluid,the analytical expressions of the apparent viscosity and the normal stress differences are given which are in a good agreement with the experimental results of Baek et al.For the fiber spinning flow of the fluid,the analytical expression of the extensional viscosity is given.

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.

A 3-Node Co-Rotational Triangular Finite Element for Non-Smooth,Folded and Multi-Shell Laminated Composite Structures

Based on the first-order shear deformation theory,a 3-node co-rotational triangular finite element formulation is developed for large deformation modeling of non-smooth,folded and multi-shell laminated composite structures.The two smaller components of the mid-surface normal vector of shell at a node are defined as nodal rotational variables in the co-rotational local coordinate system.In the global coordinate system,two smaller components of one vector,together with the smallest or second smallest component of another vector,of an orthogonal triad at a node on a non-smooth intersection of plates and/or shells are defined as rotational variables,whereas the two smaller components of the mid-surface normal vector at a node on the smooth part of the plate or shell(away from non-smooth intersections)are defined as rotational variables.All these vectorial rotational variables can be updated in an additive manner during an incremental solution procedure,and thus improve the computational efficiency in the nonlinear solution of these composite shell structures.Due to the commutativity of all nodal variables in calculating of the second derivatives of the local nodal variables with respect to global nodal variables,and the second derivatives of the strain energy functional with respect to local nodal variables,symmetric tangent stiffness matrices in local and global coordinate systems are obtained.To overcome shear locking,the assumed transverse shear strains obtained from the line-integration approach are employed.The reliability and computational accuracy of the present 3-node triangular shell finite element are verified through modeling two patch tests,several smooth and non-smooth laminated composite shells undergoing large displacements and large rotations.

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.

Co-rotational Oldroyd Fluid B Model for Spinning Flow of Liquid Crystalline Polymer

The relationship between the extensional viscosity and material parameters was studied through the analytical formulas of stress and extensional viscosity. The differential equations were solved to obtain the relationship between extensional viscosity and strain rates. The results obtained qualitatively agree with the experimental results. The study makes it practicable to simulate the rheologic behaviors of spinning flow of liquid crystalline polymer using co-rotational Oldroyd fluid B model.

Investigation of anode shaping process during co-rotating electrochemical machining of convex structure on inner surface

A novel co-rotating electrochemical machining method is proposed for fabricating convex structures on the inner surface of a revolving part.The electrodes motion and material removal method of co-rotating electrochemical machining are different from traditional electrochemical machining.An equivalent kinematic model is established to analyze the novel electrodes motion,since the anode and cathode rotate in the same direction while the cathode simultaneously feeds along the line of centres.According to the kinematic equations of the electrodes and Faraday’s law,a material removal model is established to simulate the evolution of the anode profile in co-rotating electrochemical machining.The simulation results indicate that the machining accuracy of the convex structure is strongly affected by the angular velocity ratio and the radius of the cathode tool.An increase of the angular velocity ratio can improve the machining accuracy of a convex structure.A small difference in the radius of the cathode tool will cause changes in the shape of the sidewalls of the convex structure.The width of the cathode window affects only the width of the convex structure and the inclination a of the sidewall.A relation between the width of the cathode window and the width of the convex structure was obtained.The formation process for a convex structure under electrochemical dissolution was revealed.Based on the simulation results,the optimal angular velocity ratio and cathode radius were selected for an experimental verification,and 12 convex structures were simultaneously fabricated on the inner surface of a thin-walled revolving part.The experimental results are in good agreement with the simulation results,which verifies the correctness of the theoretical analysis.Therefore,inner surface co-rotating electrochemical machining is an effective method for fabricating convex structures on the inner surface of a revolving part.

某散货船单桨、双桨推进系统燃油消耗分析

This paper presents a comparative analysis between single and twin-screw propulsion systems of a bulk carrier to evaluate the ship and propeller performance in terms of fuel consumption as well as to discuss the cavitation and noise criteria.An optimization model is developed to select the optimum propeller geometry and operational point along the engine load diagram for the selected engines of each case.The engines are selected from the same series due to the same behaviour along the engine load diagram.The propellers are selected from the B-series as fixed-pitch propellers.It has been concluded that while the components of the single-screw propulsion system are larger than the twin-screw,the single-screw propulsion system shows a reduction in fuel consumption than the twin screw by around 19%,thus affecting the amount of exhaust emissions from the ship.This model helps the ship designers to select a suitable propeller to improve the energy efficiency of the ships.

Preparation and Characterization of Thermoplastic Starch from Sugar Palm (Arenga pinnata) by Extrusion Method

Sugar palm(Arenga pinnata)starch is considered an important renewable,biodegradable,and eco-friendly polymer,which is derived from agricultural by-products and residues,with great potential for the development of biocomposite materials.This research was aimed at investigating the development of TPS biocomposites from A.pinnata palm starch using an extrusion process.Palm starch,glycerol,and stearic acid were extruded in a twin-screw extruder.Scanning electron microscopy(SEM)analysis of TPS showed that the starch granules were damaged and gelatinized in the extrusion process.The density of TPS was 1.3695 g/mL,lower than that of palm starch,and the addition of stearic acid resulted in increased TPS density.X-ray diffraction(XRD)results showed that palm starch had a C-type pattern crystalline structure.The tensile strength,elongation at break,and modulus of elasticity of TPS were 7.19 MPa,33.95%,and 0.56 GPa,respectively.The addition of stearic acid reduced the tensile strength,elongation at break and modulus of elasticity of TPS.The rheological properties,i.e.,melt flow rate(MFR)and viscosity of TPS,were 7.13 g/10 min and 2482.19 Pa.s,respectively.The presence of stearic acid in TPS resulted in increased MFR and decreased viscosity values.The peak gelatinization temperature of A.pinnata palm starch was 70°C,while Tg of TPS was 65°C.The addition of stearic acid reduced the Tg of TPS.The thermogravimetric analysis(TGA)analysis showed that the addition of glycerol and stearic acid decreased the thermal stability,but extended the temperature range of thermal degradation.TPS derived from A.pinnata palm starch by extrusion method has the potential to be applied in industrial practice as a promising raw material for manufacturing bio-based packaging as a sustainable and green alternative to petroleum-based plastics.

Experimental Study of Integration and Polyblends Performance for Improved Mixing-Extruding Machine

One improved mixing-extruding machine was introduced as the second-generation product of the mixing-molding integrated technology. In the extruding system,the conventional single screw extruder was substituted by a special conical twin-screw extruder,resulting in stronger feeding ability,more stable extrusion pressure,and better quality of products. The integrated mathematical model of mixing-extruding process was also established by theoretical derivation and optimization according to the experimental results.Then its accuracy was verified by the influences of the pressure of floating weight and the cooling water temperature of extruder on the mixing-extruding integrated process. The results showed that the changes of both parameters could give rise to the fluctuation of the temperature and apparent viscosity of polyblends, thus further influencing the screw rotation speed.

An unsymmetric constitutive equation for anisotropic viscoelastic fluid

A continuum constitutive theory of corotational derivative type is developed for the anisotropic viscoelastic fluid-liquid crystalline （LC） polymers. A concept of anisotropic viscoelastic simple fluid is introduced. The stress tensor instead of the velocity gradient tensor D in the classic Leslie-Ericksen theory is described by the first Rivlin-Ericksen tensor A and a spin tensor W measured with respect to a co-rotational coordinate system. A model LCP-H on this theory is proposed and the characteristic unsymmetric behaviour of the shear stress is predicted for LC polymer liquids. Two shear stresses thereby in shear flow of LC polymer liquids lead to internal vortex flow and rotational flow. The conclusion could be of theoretical meaning for the modern liquid crystalline display technology. By using the equation, extrusion-extensional flows of the fluid are studied for fiber spinning of LC polymer melts, the elongational viscosity vs. extension rate with variation of shear rate is given in figures. A considerable increase of elongational viscosity and bifurcation behaviour are observed when the orientational motion of the director vector is considered. The contraction of extru- date of LC polymer melts is caused by the high elongational viscosity. For anisotropic viscoelastic fluids, an important advance has been made in the investigation on the constitutive equation on the basis of which a seriesof new anisotropic non-Newtonian fluid problems can be addressed.

连接翼布局的非线性屈曲分析

以连接翼结构为研究对象,通过非线性有限元方法对其进行非线性屈曲分析,研究连接翼几何参数和载荷分布对结构非线性屈曲特性的影响规律。连接翼采用基于Co-Rotational格式的三角形平板壳单元进行建模,采用弧长法计算非线性屈曲的位移突跳现象以及后临界变形模式。研究结果表明连接翼典型的载荷-位移曲线模式包括刚度软化、位移突跳不稳定和刚度刚化三部分。连接翼夹角增大后非线性屈曲载荷因子逐步降低,但存在一个临界夹角,当角度超过临界角后载荷-位移曲线模式中的位移突跳不稳定阶段就不会出现。增加连接翼高度可提高结构的非线性屈曲载荷。在连接翼夹角不变条件下,减小下翼展长可有效提高非线性屈曲载荷,同时其载荷-位移曲线模式中的位移突跳不稳定阶段也将不存在。调整连接翼的载荷分布,将载荷更多地施加于上翼的同时减少下翼的载荷可提高结构的非线性屈曲载荷。

New conception in continuum theory of constitutive equation for anisotropic crystalline polymer liquids

A new continuum theory of the constitutive equation of co-rotational derivative type is developed for anisotropic viscoelastic fluid—liquid crystalline (LC) polymers. A new concept of simple anisotropic fluid is introduced. On the basis of principles of anisotropic simple fluid, stress behaviour is described by velocity gradient tensor and spin tensor instead of the velocity gradient tensor in the classic Leslie—Ericksen continuum theory. Analyzing rheological nature of the fluid and using tensor analysis a general form of the constitutive equ- ation of co-rotational type is established for the fluid. A special term of high order in the equation is introduced by author to describe the sp- ecial change of the normal stress differences which is considered as a result of director tumbling by Larson et al. Analyzing the experimental results by Larson et al., a principle of Non- oscillatory normal stress is introduced which leads to simplification of the problem with relaxation times. The special behaviour of non- symmetry of the shear stress is predicted by using the present model for LC polymer liquids. Two shear stresses in shear flow of LC polymer liquids may lead to vortex and rotation flow, i.e. director tumbling in the flow. The first and second normal stress differences are calculated by the model special behaviour of which is in agree- ment with experiments. In the research, the com- putational symbolic manipulation such as computer software Maple is used. For the anisotropic viscoelastic fluid the constitutive equation theory is of important fundamental significance.

液晶高分子各向异性粘弹流体拉伸流动中拉伸粘度的解析计算研究

将聚合物熔体的挤出过程看作是剪切流动主导的剪切单元,采用用液晶聚合物熔体或溶液LCP-B本构方程;采用共转Oldroyd B流体模型计算出取向运动拉伸粘度的影响.无量纲拉伸粘度随松弛时间和剪切速率的变化曲线.得到了无量纲拉伸粘度随剪切速率之间变化关系.

Modeling Study of Planar Flexible Manipulator Undergoing Large Deformation

The planar flexible manipulator undergoing large deformation is investigated by using finite element method (FEM). Three kinds of reference frames are employed to describe the deformation of arbitrary point in the flexible manipulator, which are global frame, body-fixed frame and co-rotational frame. The rigid-flexible coupling dynamic equation of the planar flexible manipulator is derived using the Hamilton’s principle. Numerical simulations are carried out in the end of this paper to demonstrate the effectiveness of the proposed model. The simulation results indicate that the proposed model is efficient not only for small deformation but also for large deformation.

A new constitutive theory for extrusion-extensional flow of anisotropic liquid crystalline polymer fluid

A new continuum theory of the constitutive equation of co-rotational derivative type was developed by the author for anisotropic viscoelastic fluid-liquid crystalline (LC) polymers (S.F. Han, 2008, 2010) . This paper is a continuation of the recent publication [1] to study extrusion-extensional flow of the fluid. A new concept of simple anisotropic fluid is introduced. On the basis of anisotropic simple fluid, stress behavior is described by velocity gradient tensor F and spin tensor W instead of the velocity gradient tensor D in the classic Leslie?Ericksen continuum theory. A special form of the constitutive equation of the co-rotational type is established for the fluid. Using the special form of the constitutive equation in components a computational analytical theory of the extrusion-extensional flow is developed for the LC polymer liquids - anisotropic viscoelastic fluid. Application of the constitutive theory to the flow is successful in predicting bifurcation of elongational viscosity and contraction of extrudate for LC polymer liquids–anisotropic viscoelastic fluid. The contraction of extrudate of LC polymer liquids may be associated with the stored elastic energy conversion into that necessary for bifurcation of elongational viscosity in extrusion extensional flow of the fluid.

Unsteady Flow of Shear-Thinning non-Newtonian Incompressible Fluid Through a Twin-Screw Extruder

The unsteady flow of viscous incompressible shear-thinning non-Newtonian fluid with mixed bound- ary is investigated. The boundary condition on the outflow is the modified natural boundary condition, it con- tains the additional nonlinear term, which enables us to control the kinetic energy of the backward flow. The global existence of weak solution is proved. The fictitious domain method which consists in filling the moving rigid screws with the surrounding fluid and taking into account the boundary conditions on these bodies by introducing a well-chosen distribution of boundary forces is used.

The hydraulic performance of twin-screw pump

Based on the computational fluid dynamics (CFD) and the experiment technology, this paper presents a new type of the twin-screw pump for the water-supply and studies its hydraulic performance with the hydraulic performance test. The internal flow characteristics and the hydraulic performance of the twin-screw pump are numerically simulated. The CFD results show that at different heads, the screw pressure gradually increases from the inlet end face along the axial direction of the screw to the outlet end face. The pressure distribution in the screw groove is relatively uniform, the screw clearance and the meshing area pressure are different from the screw groove pressure distribution. Under the same working condition of the head, the pressure distributions in the screw below and above the design speed are the same as the pressure distribution at the design speed, and with the range of the pressure value quite close. As the rotating speed increases furthermore, the flow rate and the volume efficiency of the pump both increase. At different rotating speeds, the velocity distributions along the axial direction of the screw are similar. A test rig is built, which consists of a closed-loop circuit, and the test results are found in good agreement with the CFD predictions. The experimental results show that the flow rate-head curves of the twin-screw pumps are similar at different rotating speeds. The research shows that the designed twin-screw pump enjoys a higher volumetric efficiency and a lower shaft power when the axial clearance is 0.08 mm-0.12 mm. When the clearance is 0.1 mm, the volumetric efficiency is the highest.

Investigation on Maneuverability of a Twin-Screw Ship Driven by One Screw

It is possible for a twin-screw ship that one screw failure occurs during navigation, and the maneuverability in this case should be noticed by ship designers and operators. It is of great significance to evaluate the related risk. Firstly, a mathematical model for the twin-screw ship maneuvering motion with one failed screw is developed based on the maneuvering model group(MMG) equations, and verified by the model test results.Secondly, the maneuvering motions of a twin-screw liquefied natural gas(LNG) ship with one free rotating failure screw or with one locked failure screw are simulated and compared by using the mathematical model. It is shown that the numerical modeling results are in agreement with the model test results. Compared with those of normal navigation, the port turning ability of the ship with one failed port screw is better, but the starboard turning ability and yaw checking ability become worse. The maneuverability of the ship with locked failure screw is better than that with free failure screw, although the ship speed drops obviously.