PVC装饰板材挤出模设计

介绍了一种新型ＰＶＣ塑料装饰板材挤出模的设计和研制,包括挤出机头和定型模,该设计已通过实际生产检验。     

基于三维粘弹性罚函数有限元分析的塑料异型材挤出口模设计

以Y形截面异型材挤出为研究对象,采用PTT粘弹本构模型和罚函数有限元法,对塑料熔体在挤出口模内的三维粘弹性等温流动进行了数值模拟。通过分析数值模拟得到的流速分布,修正了挤出口模的初始设计,并依据流率平衡原则来确定成型区各部分的长度。研究还表明:对于异型材挤出口模设计,不能把口模截面视作若干规则形状截面的简单几何组合,必须把其当成一个整体来对待;过渡区不仅影响成型区的流动,而且对稳流区的流动也有不可忽视的影响,设计时应对过渡区给予足够的重视。提出的异型材挤出口模设计方法可以容易地推广到更复杂截面异型材挤出口模设计中。     

基于制品壁厚中心基准尺寸的挤出模头设计理论研究

分析了聚合物PVC型坯的离模膨胀原因,在挤出模头口模缝隙设计及主体尺寸计算中,引入了离模膨胀比、膨胀牵伸综合系数,论述了基于制品壁厚中心的挤出模头设计方法,比以制品外表面为基准设计口模尺寸的方法误差更小,在此基础上推导出型材主体部分口模缝隙及尺寸的计算公式,并通过计算实例进行了验证。     

基于流率平衡的橡塑异型材挤出口模设计

为解决挤出制品的扭曲变形、起皱、破裂等问题 ,本文提出了橡塑异型材挤出口模设计的流率平衡原则 ,并据此原则通过对具体例子的流变学分析 ,提出了口模设计方法。     

塑料异形材的可调式口模

<正> 塑料型材大多是用挤出机和各种截面形状的口模生产的。管材、棒材和板材的生产都比较容易,但异形材的生产就比较困难。 一、塑料异形材生产中的难点 塑料异形材在生产当中遇到的主要困难有两个,一是模日截面相对于型材截面的修正量难于准确确定。如图1,由于在挤出过程中压缩比的存在,型材出模口之后要膨胀,所以模口截面相对于型材截面就要有个修正量h,而h受挤出压力等工艺参数和塑料     

面向数值优化设计的挤出模参数化建模方法

采用射线法和比例间隔法相结合的方法 ,利用有限元分析软件ANSYS的参数化设计语言APDL ,建立了挤出口模流道的三维模型。该方法具有适应性强、易于进行设计更改等优点 ,为建立基于CAE的挤出模优化设计和基于实例的挤出模智能设计奠定良好基础     

异型橡胶密封胶条挤出口模设计

从一种汽车用异型橡胶密封胶条挤出口模的设计及试验分析出发，对橡胶异型材料挤出口模型的设计提出了一些见解。     

挤出口模的参数化优化

应用有限元分析软件ANSYS中的参数化设计语言APDL,根据L型机头流道参数对挤出口模出口处的速度分布均匀性的影响．以口模出口处型材截面上各区域的平均流速均方差最小为优化目标,建立挤出口模的三维参数化模型,运用ANSYS中的优化工具得出最优结果。     

鱼尾形机头设计的数学分析

热塑性塑料板材与片材的挤出成型,广泛使用狭缝形口模。为使其制品具有均匀的厚度,塑料熔体沿模唇全宽方向的流速须均匀分布。本文以提高鱼尾形口模流动均匀性指数为目标,建立熔体流动模型,采用数学分析方法,推导出三种近似而具有实际意义的设计方法。通过计算机编程处理所得平面坐标描述图以及示例计算表明,选取流道尺寸最佳值,便可获得高流动均匀性指数。据此考虑所设计的鱼尾形机头,其所生产的板材或片材必然具有良好的力学性能。因此,本文对鱼尾形机头设计具有普遍的指导意义。     

金属型材螺杆挤出机

为降低生产成本和提高生产率,美国哥伦比亚大学最近研制出一种金属螺杆挤出机,用于连续生产金属型材。该挤出机类似于塑料挤出机,金属液由料口直接喂入,通过机头口模连续挤出固态金属型材。用该机对Pb-2.0%Sb合金进行板材加工试验,结果表明,不仅生产     

7A52铝合金搅拌摩擦焊工艺优化

接头强度是搅拌摩擦焊接头性能的一个重要指标,通过搅拌头旋转频率、焊接速度和轴肩下压量等焊接工艺参数的不同组合制备了35个7A52焊接试板,对试板进行拉伸试验检测了接头的抗拉强度,建立并分析了焊接接头抗拉强度与焊接工艺参数之间的回归模型,搅拌头旋转频率n,焊接速度v和轴肩下压量d<,ta>单独变化时,接头抗拉强度都有峰值...     

The effect of polypyrrole coatings on the adhesion and structure properties of UHMWPE fiber

To improve the adhesion between ultrahigh molecular weight polyethylene (UHMWPE) fiber and polymer matrix, pyrrole is oxidatively polymerized on the UHMWPE fiber surface continuously. The micro-composite of polypyrrole (PPy)-coated fiber/epoxy was prepared and the fiber was studied by interfacial shear strength (IFSS) through a single fiber pull-out method. Compared with the UHMWPE fiber as-received, the mean value of IFSS between PPy-coated UHMWPE and epoxy increased from 1.06 MPa to 5.72 MPa. In addition, the surface morphology and structure of PPy-coated UHMWPE fiber were studied by SEM, FT-IR, DSC and DMA. The results showed that PPy-coated UHMWPE fiber surface was observed with some particles attached. Although there is no chemical interaction between PPy and UHMWPE chains, PPy has some interaction with UHMWPE molecular chains according to the results of DMA. The PPy coatings have an effect on the adhesion may be associated with the roughened surface of the fiber and upon intermolecular interaction.     

Tribological characterization of surface modified UHMWPE against DLC-coated Co–Cr–Mo

The generation of wear particles from the ultra-high molecular weight polyethylene (UHMWPE) counter-face of Co–Cr–Mo/UHMWPE sliding pair is relatively high. These polyethylene wear particles lead to osteolysis and that result in the failure of the implant made with the Co–Cr–Mo/UHMWPE sliding pair. Hence, an investigation has been carried out to enhance the wear resistance of UHMWPE by surface modification of one or either of the sliding surfaces. Tribological characterizations were carried out on good quality diamond-like carbon (DLC) coatings prepared on UHMWPE with and without prior C-ion implantation by filtered cathodic vacuum arc (FCVA) technique in conjunction with high substrate pulse biasing, sliding against uncoated and DLC-coated Co–Cr–Mo.

The evaluations are categorized into two groups: (1) unmodified and DLC-coated UHMWPE with and without prior carbon implantation sliding against uncoated Co–Cr–Mo, (2) DLC-coated UHMWPE with and without prior carbon implantation sliding against DLC-coated Co–Cr–Mo. The study reveals that by coating the UHMWPE with DLC coating protects the UHMWPE surface. However, the DLC coating causes severe Co–Cr–Mo wear. Coating both the sliding surfaces with DLC coating reduces the wear rates of the sliding surfaces to a greater extent. The DLC-coated UHMWPE with prior carbon implantation did not show any superior behaviour over that without prior carbon implantation.     

DLC and UHMWPE as hard/soft composite film on Si for improved tribological performance

The main purpose of this study is to explore the advantages of using a composite thin film of ultra high molecular weight polyethylene (UHMWPE) on a hard diamond like carbon (DLC) coating deposited on Si, for high wear life and low coefficient of friction. The experiments are carried out using a ball-on-disc tribometer at a constant linear speed of 0.052 m/s. A 4 mm diameter silicon nitride ball with a normal load of 40 mN is used as the counterface. The tribological results are discussed on the basis of hardness, elastic modulus, contact area, contact pressure and optical images of surface films. As a result of higher load carrying capacity (high hardness and elastic modulus), the wear life of Si/DLC/UHMWPE coated layer is approximately five times greater than that of Si/UHMWPE. Looking at the film thickness effect, UHMWPE film shows maximum wear resistance when the film is of optimum thickness (6.2 μm-12.3 μm) on DLC. Wear mechanisms of different UHMWPE thicknesses for Si/DLC/UHMWPE film are explained using optical microscopy of worn surfaces. Further, the use of perfluoropolyether (PFPE) ultra-thin film as the top layer on the composite coatings reduces the coefficient of friction to very low values (0.06-0.07) and increases the wear life of the films by several folds.     

Effect of Welding Parameters on the Microstructure and Strength of Friction Stir Weld Joints in Twin Roll Cast EN AW Al-Mn1Cu Plates

Twin roll cast EN AW Al-Mn1Cu plates were butt welded with the friction stir welding process which employed a non-consumable tool, tilted by 1.5° and 3° with respect to the plate normal, rotated in a clockwise direction at 400 and 800 rpm, while traversing at a fixed rate of 80 mm/min along the weld line. Microstructural observations and microhardness tests were performed on sections perpendicular to the tool traverse direction. Tensile tests were carried out at room temperature on samples cut perpendicular to the weld line. The ultimate tensile strength of the welded EN AW Al-Mn1Cu plates improved with increasing tool rotation speed and decreasing tool tilt angle. This marked improvement in ultimate tensile strength is attributed to the increase in the heat input owing to an increased frictional heat generation. There appears to be a perfect correlation between the ultimate tensile strength and the size of the weld zone. The fracture surfaces of the base plate and the welded plates are distinctly different. The former is dominated by dimples typical of ductile fractures. A vast majority of the intermetallic particles inside the weld zones are too small to generate dimples during a tensile test. The fracture surface of the welded plates is thus characterized by occasional dimples that are elongated in the same direction suggesting a tensile tearing mechanism.     

Influence of tool plunge depth and welding distance on friction stir lap welding of AA5454-O aluminum alloy plates with different thicknesses

AA5454-O aluminum alloy plates with thicknesses of 1.4 and 1.0 mm were friction-stir-lap-welded (FSLWed).The influences of the tool plunge depth and welding distance on surface appearance,macrostructure and mechanical properties of the FSLWed plates were experimentally investigated.The tensile shear load of the FSLWed plates was compared with that of the adhesive-bonded plates.Defect-free FSLWed zones were successfully obtained in all the tool plunge depths and the welding distances.The FSLWed zones exhibited the relatively smooth surface morphologies.Under all the FSLWed conditions,the FSLWed zone exhibited higher average hardness than the base metal.In addition,the upper plate exhibited a higher average hardness than the lower plate,although there was no special tendency in spite of the change in the tool plunge depth and the welding distance.The maximum tensile shear load of the FSLWed plates was much higher than that of the adhesive-bonded aluminum alloy plate.Especially,under the FSLW condition of the plunge depth of 1.8 mm and the welding distance of 40 mm,the tensile shear load of the FSLWed plate reached a level about 41% greater than that of the adhesive-bonded aluminum alloy plate.In addition,the maximum tensile shear load of the FSLWed plate was increased with the increase of the welding distance.     

Investigation of the material flow and texture evolution in friction-stir welded aluminum alloy

The material flow and crystallographic orientation in aluminum alloy sheets joined by friction stir welding (FSW) were investigated by electron back scattered diffraction (EBSD). The microstructure and microtexture of the material near the stir zone was found to be influenced by the rotational behavior of the tool pin. It was found that, during FSW, the forward movement of the tool pin resulted in loose contact between the tool pin and the receding material at the advancing side. This material behavior inside the joined aluminum plates was also observed by an X-ray micrograph by inlaying a gold marker into the plates. As the advancing speed of the tool increases at a given rotation speed, the loose contact region widens. As the microtexture of the material near the stir zone is very close to the simple shear texture on the basis of the frame of the tool pin in the normal and tangent directions, the amount of incompletely rotated material due to the loose contact could be estimated from the tilt angle of the shear texture in the pole figure around the key hole.     

Friction stir butt welding of A5052-O aluminum alloy plates

Friction stir butt welding (FSW) between A5052-O aluminum alloy plates with a thickness of 2 mm was performed.The rotation speeds of the welding tool were 2000 and 3000 r/min,respectively.The traverse speed was ranged from 100 mm/min to 900 mm/min.The defect-free welds with the very smooth surface morphology were successfully obtained,except for at the welding condition of 3000 r/min and 100 mm/min.The onion ring structure was observed in the friction-stir-welded zone (SZ) at the condition of 2000 r/min and 100 mm/min.For all the welding conditions,the grain size of the SZ was smaller than that of the base metal,and was decreased with the decrease of the tool rotation speed and with the increase of the tool traverse speed.The stir zone exhibited higher average hardness than the base metal.The decrease of the tool rotation speed and the increase of the tool traverse speed resulted in the increase in the average hardness of the SZ.The tensile strength of the FSWed plates was similar to that of the base metal,except for at the welding condition of 3000 r/min and 100 mm/min.The total elongation of the FSWed plates was lower than that of the base metal.     

Analysis of process parameters effects on dissimilar friction stir welding of AA1100 and A441 AISI steel

Abstract

A prominent benefit of friction stir welding process is to join plates with dissimilar material. In this study, an attempt is made to find effects of tool offset, plunge depth, welding traverse speed and tool rotational speed on tensile strength, microhardness and material flow in dissimilar friction stir welding of AA1100 aluminium alloy and A441 AISI steel plates. Here, one factor at a time experimental design was utilised for conducting the experiments. Results indicated the strongest joint obtained at 1·3?mm tool offset and 0·2?mm plunge depth when the tool rotational speed and linear speed were 800?rev min^??1 and 63?mm min^??1 respectively. The maximum tensile strength of welded joints with mentioned optimal parameters was 90% aluminium base metal. Fracture locations in tensile test at all samples were in aluminium sides. Owing to the formation of intermetallic compounds at high tool rotational speed, the microhardness of joint interface goes beyond that of A441 AISI steel.     

Influences of tool plunge speed and tool plunge depth on friction spot joining of AA5454-O aluminum alloy plates with different thicknesses

AA5454-O aluminum alloy plates with the thicknesses of 1.4 and 1.0 mm were friction-spot-joined (FSJed).The plunge speed of the joining tool was changed in a range of 100 500 mm/min under a constant rotation speed of 500 r/min.The plunge depth was ranged from 1.6 mm to 2.2 mm.The tool plunge speed did not make a remarkable effect on the surface appearance and macro-structure of the FSJed zone.The average hardness of the FSJed zone was greater than or equal to that of the base metal.However,there was no remarkable tendency in the average hardness change of the FSJed zone in spite of the variation in the tool plunge speed and tool plunge depth.The increase of the tool plunge depth resulted in the increase of the tensile shear load.However,the change of the tool plunge speed did not lead to the remarkable variation in the tensile shear load of the FSJed plates.It was noteworthy that the FSJed plate exhibited the highest tensile shear load of about 4.0 kN.