改善挤出吹塑制件壁厚均匀性的几种方法

概述了近年来改善挤出吹塑中空制件壁厚不均匀的方法及其进展,包括新牌号的树脂,新的型胚壁厚控制技术及新的挤出吹塑成形工艺。型胚控制技术主要介绍了异型口模和可调机头;新成形工艺包括3D中空吹塑,真空吸塑与挤出吹塑相结合的技术,型坯温差法及高压低温挤出吹塑技术。     

聚合物在等温圆管口模中流动的数值模拟

以挤出圆管为研究对象,采用PTT粘弹本构模型和通用的有限元POLYFLOW软件,对塑料熔体在不同挤出口模内的二维粘弹性等温流动进行了数值模拟。通过数值模拟得出了CPU时间、压力和离模膨胀比等结果。研究表明,过渡段的设计会对挤出压力产生明显的影响,但对离模膨胀比没有影响,用三次插值多项式表征的流线型口模具有较小的挤出压力。     

Fracture life prediction and sensitivity analysis for hollow extrusion dies

It has been reported in literature that extrusion dies most often fail by fatigue fracture. Experimental studies have shown that cracks pre‐exist in dies because of various factors including machining, heat treatment and surface hardening. High levels of repeated mechanical and thermal loads result in crack propagation leading to ultimate fracture failure. In an earlier work by the authors, a simplified approach of plate‐with‐edge‐crack was used to develop a fracture mechanics based fatigue life prediction model for tube dies. In the current work, extrusion die is modeled as a pressurized‐cylinder‐with‐internal‐crack, a more realistic approach for a hollow (tube) die. Stochastic nature of various fatigue‐related die parameters has been used to reflect their variability. Monte Carlo simulation has been performed to forecast fracture failure of extrusion dies under a given set of operating conditions and mechanical properties. Predicted mean‐time‐to‐failure is quite close to actual average extrusion die life data from the industry. Using tube die as a basis, fracture life of other hollow profiles can be estimated through their shape complexity values. Analysis has also been carried out to evaluate how sensitive fracture life of hollow extrusion dies is to material and process parameters. Major findings are that die life is highly sensitive to initial crack size, wall thickness, profile outer diameter and billet length; moderately sensitive to Paris constant and extrusion ratio; and only slightly sensitive to fracture toughness and ram speed. These results can contribute to a deeper understanding of the factors responsible for fracture failure of an extrusion die exposed to thermo‐mechanical fatigue environment.     

振动力场对聚合物挤出胀大的影响

为了改善聚合物材料的挤出胀大现象,将振动力场引入聚合物的挤出过程.采用动态毛细管流变仪对不同振动参数下的挤出胀大进行研究,建立了相应的物理模型和数学模型,并借鉴前人的工作成果,运用数学推导得到了挤出胀大与振动参数间关系的解析式.研究表明:随着振动频率和振幅的增加,挤出胀大呈非线性减少,并最后趋于稳定.     

Die swell behavior of liquid crystalline mesophase pitch

Die swell of a spinnable mesophase pitch was explored using a fiber spinning apparatus with varied capillary geometries and processing conditions. It was found that the die swell decreased with increased shear rate and increased with a rise of temperature. A nearly constant die swell value can be reached as shear rate gets high enough for different temperatures, and it decreased with increased die angles, but maintained unchanged for capillaries with different length-to-diameter ratios. For orifice die, the die swell ratios were found to be affected little by the extrusion rate and the temperatures. The texture examination of the extrudates from orifice die and dies with capillaries shows that the extensional flow produces high molecular orientation, and the shear flow-induced tumbling might store elastic energy that will be recovered at the die exit.     

Elastic behaviour of polyvinyl chloride melts

A study has been made of the elastic behaviour of Polyvinylchloride commercial samples at high shear stresses, under similar conditions to those used in the processing industry, by means of an extrusion capillary rheometer.The influence in the die swell of variables as molecular weight, temperature and shear rate has been studied. Results are in agreement with general literature data.Smooth extrudates are obtained only in the zone of intermediate shear rates. In this zone it is observed that the die swell increases with shear rate.     

温度对挤出吹塑制件壁厚分布及性能的影响

为实现挤出吹塑制件壁厚均匀分布和提高制件性能,国内外学者从挤出吹塑过程的3个阶段:型坯成型、型坯吹胀以及制品冷却与固化阶段,研究了温度对制件壁厚分布及其性能的影响情况.分析了温度对其成形及性能的影响,综述了前人研究成果.     

聚合物熔体复合挤出胀大过程的数值模拟及可恢复弹性形变分析

建立了两种聚合物熔体流经矩形流道共挤出的三维数值计算模型,采用有限元方法数值模拟了共挤出成型过程及胀大过程,得到了速度场、压力场、应力场,并利用数值计算方法得到了共挤出流动过程的可恢复弹性形变场,分析了挤出胀大率以及可恢复弹性形变的变化过程。结果表明,在共挤出流动的胀大段,共挤出界面的形状和位置发生了改变;经矩形流道共挤出得到的挤出胀大末端截面形状为不对称的鼓形;在共挤出界面附近可恢复弹性形变值存在极值,运用数值方法计算可恢复弹性形变可以对流动过程中可能存在的缺陷进行预测。     

高分子材料的挤出胀大和熔体破裂

挤出胀大和熔体破裂不仅是高分子流变学研究的热点,而且对工业生产有重要的指导作用.文中回顾了近五年来在挤出胀大和熔体破裂方面的研究进展,并简要介绍了国内外降低或消除挤出胀大和熔体破裂的主要方法.     

Pb-GF挤压包覆间隙的数值计算及实验研究

铅包覆玻璃纤维属于塑性材料包覆脆性材料,包覆条件是建立在玻璃纤维不发生变形的情况下,为此,入丝模芯顶端与挤压模口之间的间隙即包覆间隙的优化选择是成形工艺的关键问题.本文采用上限法对包覆挤压过程建立了数值模型,从能量的角度对包覆挤压过程进行了数值计算,将包覆间隙作为一变量引入功的表达武中,并通过数值计算软件给出了数值解,得出包覆间隙的最佳理论值.通过大量的实验证明了数值计算结果与实验结果基本吻合.运用本文结果可以确定不同规格的复合丝材成形时包覆间隙的大小,指导模具设计和工艺参数确定,具有工程意义.     

薄壁管壳体环矢挤压缩径工艺仿真分析与研究

目的 针对空心薄壁件在缩径成形工序中力学性质难以观测且缩径成形加工效率较低的问题,提出一种使用18瓣环矢挤压模具进行环矢挤压一次性成形的缩径工艺,并研究了该工艺下薄壁管壳体的弹塑性变形规律。方法 以外径6.3 mm、壁厚2 mm、颈缩宽度1 mm的小尺寸薄壁管壳体（Q255材料）为研究对象,基于Barlat’96屈服准则和M–K沟槽理论,结合L.H.Donnell理论,建立管壳体环矢挤压缩径的塑性微元应力模型,通过ANSYS软件建立环矢挤压缩径工艺有限元模型,并进行数值模拟分析,获得管壳体环矢挤压过程中内壁面和颈缩区厚度方向的应力分布规律;最后进行实验验证,利用千分尺测量外径,采用应力测定仪测量中心位点应力,验证了该工艺下仿真结果的准确性。结论 颈缩区域宽径比越大,缩径成形越远离弹性区;内壁面的应力整体呈凸状分布;卸载后,壁厚方向的残余应力呈从外壁到内壁逐渐增大的线性分布趋势,缩径区中心点最大残余等效应力为319.76MPa,分布在挤压部位的内表面;经实验验证,内壁面中心位点的最大残余应力为183MPa,其与仿真分析结果（202.5MPa）的吻合度高达91.5%,验证了仿真结果的准确性...     

超声辐照对聚丙烯加工及结构性能的影响

研究了聚丙烯（PP）在超声辐照作用下的挤出加工特性、力学性能及结晶行为的变化,发现适宜的超声辐照作用,可显著降低挤出压力、表观粘度、提高挤出量、并使挤出物出口膨胀降低,表观质量有所改善,而聚丙烯的力学性能基本不变,此外,聚丙烯的DSC曲线及X射线衍射（WAXD）谱表面PP结晶结构发生了变化,β晶含量增加。     

In-process rheometry as a PAT tool for hot melt extrusion

Real time measurement of melt rheology has been investigated as a Process Analytical Technology (PAT) to monitor hot melt extrusion of an Active Pharmaceutical Ingredient (API) in a polymer matrix. A developmental API was melt mixed with a commercial copolymer using a heated twin screw extruder at different API loadings and set temperatures. The extruder was equipped with an instrumented rheological slit die which incorporated three pressure transducers flush mounted to the die surface. Pressure drop measurements within the die at a range of extrusion throughputs were used to calculate rheological parameters, such as shear viscosity and exit pressure, related to shear and elastic melt flow properties, respectively. Results showed that the melt exhibited shear thinning behavior whereby viscosity decreased with increasing flow rate. Increase in drug loading and set extrusion temperature resulted in a reduction in melt viscosity. Shear viscosity and exit pressure measurements were found to be sensitive to API loading. These findings suggest that this technique could be used as a simple tool to measure material attributes in-line, to build better overall process understanding for hot melt extrusion.     

Modeling of Industrial Polymer Processes: Injection Molding and Blow Molding

In the last twenty years injection molding and blow molding have seen a rapid growth due to the development of new application areas in the automotive, sports and leisure, electronics, transportation and packaging industries. This success can be traced to the optimization of existing processes and to the development of new processing techniques employing novel concepts such as gas-assisted injection molding, co-injection, and 3D and sequential blow molding. The complexity of these new molding techniques calls for a much better understanding of the material behavior during the basic stages of the process and its relation to the properties and performance of the final part. These characteristics are directly dependent upon die and mold designs and on the operating conditions during extrusion, injection, inflation and cooling in the mold.In this paper we will demonstrate how the numerical simulation of the individual steps of the process can be used to optimize the process and product performance of industrial parts. In the case of injection molding, special interest will be devoted to the numerical prediction of the filling phase for both thin and thick parts. For blow molding the prediction of material behavior during clamping and inflation will be shown and related to final part thickness distribution, parison programming and preform design.     

大型复杂薄壁铝合金空心型材挤压成形工艺

目的 解决大型复杂薄壁铝合金空心型材挤压过程中材料流速均匀性控制难,以及模具局部应力集中导致模具寿命低、挤压型材尺寸稳定性差的问题。方法 采用有限元模拟方法对此类典型型材挤压过程进行仿真分析,根据仿真结果中型材出口材料流速分布情况,通过调控不同部位材料流入量及材料流动阻力,并以型材出口流速差和流速均方差（SDV）作为衡量挤压过程中材料流速均匀性的指标,逐步迭代优化模具结构以提高材料流动均匀性;根据仿真结果中挤压模具应力分布情况,以模具最高应力作为衡量模具强度的指标,逐步迭代优化模具结构以减小模具应力。结果 通过迭代仿真依次优化模具工作带长度、分流孔尺寸、阻流块高度等参数,最终型材出口流速差由25.07 mm/s降至2.72 mm/s,流速均方差由9.84 mm/s降至0.72 mm/s;通过迭代仿真优化焊合角度,最终模具最高应力由945 MPa降至863 MPa。采用基于有限元仿真优化结构的挤压模具成功制备了合格的铝合金型材样件,挤压试验结果与数值模拟结果吻合。结论 通过优化模具工作带长度、分流孔尺寸及阻流块高度,调控不同部位材料流入量及材料流动阻力,能够有效解决大型复杂薄壁铝合金空心...     

汽车变速器结合齿温锻-冷整形复合精锻工艺及模具研究

目的解决汽车变速器结合齿整体成形过程中的难充满、尺寸精度差、脱模困难等问题。方法对结合齿精锻成形过程进行了数值模拟和工艺参数的优化,并对比模拟分析了结合齿齿高和齿厚方向的15组数据。结果得出了最佳的齿高和齿厚方向余量,分别为0.5 mm和0.1 mm;采用镶块剖分式模具结构和径向挤压成形技术来解决结合齿倒锥成形和脱模等问题,延长了模具寿命。结论采用温锻-冷整形复合精密锻造工艺,结合齿的表面质量好,产品精度高。     

Plasma‐Duplexschichten auf Aluminium Strangpresswerkzeugen

In the extrusion process of aluminium alloys at elevated temperature, the dies are used under very severe thermal and mechanical stresses. Furthermore slide friction and adhesive wear occur in the interaction zone between extrusion die and extrusion product. This tribological process has significant effects in several aspects such as the surface quality, the dimensional tolerances of extruded products and the lifetimes of the dies. To improve the die performance and the quality of aluminium products, a duplex process combining a plasma nitriding (PN) pretreatment and a plasma‐assisted CVD or PVD was applied on the extrusion dies, which are made of hot working steel (X38Cr MoV51). The duplex layers are produced at a temperature of 530°C This is below the tempering temperature of the hot working steel. The effects of process parameters during plasma nitriding, such as duty cycle, nitrogen concentration in process gas and nitriding time, are investigated. The optimized modification of the die surface has been achieved. The duplex layers (TiBN‐, CrN‐ and W‐C:H‐films on the plasmanitriding films) have higher macro hardness (HV9.5) and critical load, in comparison with the conventional films without plasma nitriding pretreatment. The performance of the coated dies are examined by means of a direct extrusion. It is confirmed that the duplex layers suit best for the extrusion at elevated temperature.     

Melt-state shear flow and elasticity of a thermoplastic fluorosulphonated—PTFE copolymer

Some rheological properties of a perfluorosulphonated PTFE copolymer have been measured in order to characterise the melt-state viscous and elastic behaviour of a thermoplastic precursor of Nafion®, an ion-selective membrane used in the electrochemical industry. Steady-state shear viscosity measurements show conventional pseudoplastic flow behaviour over a wide temperature range, under high shear conditions. These data have been modelled to a high level of accuracy using polynomial simulations to obtain Carreau model coefficients and flow activation energies. Using an orifice die in a capillary rheometer, calculated extensional viscosity data are shown to decrease with stress and are more temperature-sensitive than shear viscosity. Although die swell increases with shear rate in a conventional manner, unusual and complex die swell data (at a fixed shear stress) have been obtained in response to an increase in process temperature. This behaviour is attributed to the breakdown of a small-scale network of domains and ordered crystalline material in the amorphous matrix of the precursor, as exemplified by a very broad melting endotherm. Different modes of deformation have been proposed to explain the rheological data observed across the process temperature range. The observed changes to the flow mechanism and elastic character of the melt carry practical implications for the extrusion processes and developed microstructure of film products manufactured from this precursor copolymer.     

Theoretical research of co-extrusion process of aluminum AA3003/AA7072 clad alloys

The vaporizer tube base material and the clad material were simultaneously extruded to produce a tube having a smooth surface and a clad layer having excellent coupling characteristics. The process of controlling the thickness of the clad layer by simultaneously extruding two metals with different mechanical properties requires a high degree of precision compared to a single metal extrusion process and requires careful consideration for setting appropriate manufacturing parameters. In setting these variables, the trial and error approach by repeated extrusion results in excessive research cost and time consuming. Therefore, in this study, computer simulation was carried out to investigate the relationship between shape and process parameters of extruded materials. The process parameters applied to this simulation are the friction coefficient between the two materials and the angle of the die, and the thickness variation and uniformity of the clad material after extrusion were investigated. From the simulation results, as the friction coefficient of the matrix and the clad material increases, the clad layer thickness of the extruded material becomes close to the theoretical value and exhibits a uniform value.     

基于 Deform-3D 的车用下轴套零件冷挤压模具结构优化设计

目的分析挤压成形中车用下轴套零件成形表面出现的折叠缺陷,优化挤压上凹模的底部出口斜度、下凹模的入口斜度和挤压深度等主要成形工艺参数。方法采用DEFORM-3D软件,对汽车下轴套零件的冷挤压成形工艺进行了系统的有限元数值模拟试验。结果挤压成形模具结构设计不合理,导致在成形过程中模具分型面处金属出现汇流并形成折叠。结论通过优化挤压模具结构,使金属成形良好,无折叠缺陷出现,最终获得了较为合理的冷挤压模具结构。