注射成型过程中非牛顿塑料熔体的流变特性

在探讨塑料熔体粘度模型的基础上，根据塑料熔体在注射成型过程中的流动特点，讨论了一种能够在加工温度和压力条件下，剪切速率在l0～10^3s^-1的变化范围内，相当精确地描述高聚物流变特性的拈度模型。重点讨论了模型的参数拟合和适用范围，为注射模具设计和成型模拟提供了科学依据。     

塑料充模流动粘性模型研究

对多种塑料在不同温度下的剪切速率一稳态剪切粘度数据进行Cross粘性模型参数拟合，得到了表征材料粘度的模型参数(B，Tb，τ^*，n)。其拟合效果良好，能较准确地描述塑料熔体在一定剪切速率和温度范围内的粘流特性，为工程计算和塑料熔体模流分析提供了数据支持。结果表明，该方法有较广泛的适用性。     

高速微注射成型中熔体充填模式及裹气机理研究

塑料为了准确模拟聚合物熔体在型腔中的流动及前沿位置和形态,建立了熔体、气体两相流流动模型,构造了熔体流动的黏弹性本构关系,用无量纲方法建立了熔体流动前沿的气体、熔体流动的统一控制方程和本构方程,并采用水平集方法预测和跟踪熔体流动前沿,模拟了熔体在低速、中速、高速条件下的流动状态和充填模式,分析了高速微注射成型中气孔产生的原因和可能出现的位置,开展了实际产品的高速微注射成型实验,比较了模拟结果和实验结果。研究表明,熔体充填模式与注射速度、材料特性、型腔尺寸密切相关,在喷射充填模式下可能产生裹气。     

多级注射成型工艺的设计

通过对多级注射成型工艺的研究发现,多级注射成型工艺的核心是如何进行多级分段和如何选择工艺参数。在介绍塑料熔体充模流动特征的基础上,通过系统分析理想充模模型,并联系多级注射原理,提出了分段设计原则及参数选择方案。     

注射微泡成型熔体固化过程数值模拟

通过研究微孔塑料注射成型熔体固化过程,基于合理的假设并进行必要的简化,建立了熔体固化过程的数学模型。采用有限元/有限差分耦合法对模型进行求解,预测固化过程型腔内的压力分布,以帮助注射成型加工人员确定工艺参数,提高第一次试模成功率。     

注塑级塑料粘性模型研究

本文在探讨塑料熔体粘性流动模型的基础上,使用幂律模型和Cross模型对几种塑料熔体流变数据进行处理,得出各自的拟合常数,并对拟合结果进行分析比较.为塑料模设计和塑料模CAD及CAE技术提供了理论依据.     

塑料注射成型熔体前沿的流动模拟

讨论了塑料注射成型流动过程分析中熔体前沿喷泉效应的近似处理方法和数值分析方法。     

真空辅助成型用不饱和树脂的粘度模型和流变特性分析

测试并分析了VARI用不饱和聚酯树脂DS326PT-1在动态升温及恒温条件下的粘度变化,建立了工程粘度模型,并通过该模型来预测适用于VARI(真空辅助成型工艺)的低粘度工艺窗口。实验数据表明,该粘度模型与实验结果吻合良好,可为VARI工艺过程的模拟与参数优化提供有效的参考数据。     

聚合物流变性能对共注射成型的影响

在共注射成型多相分层流动充模成型机理的基础上，揭示了芯壳层熔体对共注射成型的分层界面形貌和芯层熔体前沿突破的影响，并模拟了芯壳层熔体粘度比对共注射成型的影响，建立了芯壳层熔体粘度与分层界面和前沿移动界面菜貌的关系。本文的模拟研究结果与一些文献的实验结果相吻合。     

动态成型注塑螺杆熔体输送能力的研究

根据动态注射成型时螺杆的工作特点，采用自行修正的Tanner本构方程研究了聚合物熔体在螺槽中的等温流动。同时，近似地给出了振动力场下注塑螺杆熔体输送能力的表达式，理论分析了振动参数对沿程压力降及动态成型熔体输送能力的影响。结果表明，振动力场使塑化过程中聚合物的粘度降低，流动阻力减小。沿螺槽方向的平均压力降减小，在保持成型条件不变的情况下，施加振动可以提高熔体输送能力。     

Molding of reprocessed thermoplastics with preplastication injection molding

The injection molding of reprocessed plastics with a preplastication plunger injection‐molding machine was investigated with a focus on the processing conditions. The process of the filling of the resin into the mold is much better controlled with preplastication than with processing in a conventional injection‐molding machine. Reprocessing of the resin leads to a reduction in molecular weight due to drastic changes in the resin morphology, thereby causing a reduction in melt viscosity. Direct experimental evidence for reduced viscosity was obtained from measurements of the filling pressure recorded on the machine and also with a melt‐flow indexer. The results of this study provide a practical solution for reducing the resin temperature when reprocessed resin is used in the injection molding of plastics. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 1455–1461, 2001     

聚合物熔体流变性能对气辅注塑工艺的影响

应用ＨｅｌｅＳｈａｗ物理模型和改进的Ｃｒｏｓ流变模型及有限元算法对５种聚丙烯的气辅注塑过程进行模拟,研究不同聚丙烯材料在充模速度相同的条件下的压力及锁模力变化规律。结果表明,气辅注塑在气体注射后与传统注塑有较大差异,所需压力、锁模力均比传统注塑有显著降低,且聚合物的熔体流动速率越小,气体注射后产生的压力降越大,表明在生产中应尽可能选用高熔体流动速率树脂以利于气辅注塑工艺。     

Control of polymer properties by melt vibration technology: A review

This paper reviews the technology of melt vibration (more specifically at low frequency) to reduce viscosity during processing of plastics and to enhance mechanical performance of the solidified parts. The effect of vibration frequency and amplitude on melt viscosity is explained in terms of shear-thinning criteria. The effect of pressure and temperature on shear thinning is also reviewed to predict how these variables interfere with melt vibration. Practical applications of the principles of melt vibration are provided in injection molding, extrusion and compression molding/thermoforming, from reduction of viscosity to lowering processing temperature and pressure to the elimination of melt defects and weld lines, to the enhancement of mechanical properties, stiffness and strength, by modification of the amorphous and semicrystalline texture and orientational state. Commercially available equipments are reviewed. Results showing the effect of melt vibration during processing for two classical polymers, polystyrene and polypropylene, are discussed. The paper concludes on the remaining challenges to bring the benefits of the new technology to full commercialization.     

Effect of dissolved gas on the viscosity of HIPS in the manufacture of microcellular plastics

The microcellular plastics (MCPs) process is a foaming process that has been developed to reduce the weight of a product without significant changes to the mechanical properties. To apply microcellular plastics to mass production systems such as extrusion, injection molding, and blow molding, research must be done on material properties, such as viscosity, glass transition temperature, and melt index of polymer resin. Among the properties, it is critical to predict the change in viscosity with the amount of inert gas, which can be an index of the injection molding working condition of polymer resin. The purpose of this paper is to study the relationship between the amount of dissolved gas and the viscosity of high impact polystyrene (HIPS) resin in extrusion. The experiment was carried out with newly designed gas supply equipment and with a screw and die modified for MCPs. In addition, a pressure gauge was set up on the end of a barrel for measuring the pressure change. The experiment has shown that the viscosity of polymer decreases with increasing amounts of inert gas. A new model was applied to estimate the viscosity change as a function of the amount of dissolved gas.     

气体辅助注射成型充填过程的数值模拟

描述了气体辅助注射成型的工艺过程及熔体充填和气体穿入的数学模型,采用有限元/有限差分/控制体积法计算充填阶段的压力场和温度场,确定熔体前沿和熔体/气体界面两类移动边界,并对典型制件充模过程进行了模拟.     

气辅注射成型矩形腔中熔体流动的数值模拟

应用Hele-Shaw物理模型和改进的Ｃross流变模型对辅助射成型过程中充填区域内熔体的流动进行数值模拟,采用控制体积法对充模过程中的熔体前沿、熔体－气体边界进行跟踪,运用有限元／有限差分混合数值方法求解气体注射阶段的速度场、压力场、温度场,以图表的形式列举了不同时刻压力场的分布和充模过程中的流线图。在计算过程中,采用压力场和温度场耦合的方法。     

脉动压力诱导注射成型充模过程熔体表观黏度的实时测量

以脉动压力诱导注射成型充模过程浇口流道中熔体壁面表观剪切黏度的数学模型为基础,通过实时测量记录螺杆位置变化以及浇口流道两端熔体压力变化,表征脉动压力诱导注射成型充模过程熔体实时表现剪切黏度的方法,通过实验研究发现,脉动压力的引入使充模过程、熔体的剪切应力和表观剪切黏度降低,同时加剧了熔体的剪切速率变化,在强烈的振动条件下会引起动态充模过程中某些时刻出现断流现象.     

Dependence of bulk viscosity of polypropylene on strain,strain rate,and melt temperature

The relations between bulk viscosity, strain, strain rate, and melt temperature of polypropylene are investigated in uniaxial compression similar to the measurement of PVT diagram of a polymer. A new and more practical bulk viscosity model for the simulation of injection molding is proposed. The bulk viscosity increased with the increase of compression deformation and decreased when the compression speed and the melt temperature are higher. This dependency is attributed to the orientation and occupancy of the molecule within the free interstitial space. In addition, the magnitude of the bulk viscosity was found to be significantly greater than the shear viscosity at high compression deformation and low strain rate. Thus, not only shear viscosity but also the bulk viscosity should be considered in the simulation of the packing‐holding stage of the plastic injection molding process. POLYM. ENG. SCI., 57:830–837, 2017. © 2016 Society of Plastics Engineers     

动态充模过程熔体表观黏度的实时测量与研究

修正了脉动压力诱导注射成型充模过程浇口流道中熔体壁面表观剪切黏度的数学模型,并介绍了建立在此基础上的通过实时测量并记录螺杆位置变化以及浇口流道两端熔体压力变化来表征脉动压力诱导注射成型充模过程熔体实时表观剪切黏度的方法,通过实验研究发现,脉动压力的引入对熔体的实时表观剪切黏度产生了深刻的影响,且降低了充模过程单振动周期内壁面熔体的平均表观剪切黏度及受到的平均剪切应力。在此过程中,还提出了特定振动参数下熔体剪切应力与剪切速率之间相位角的计算方法。     

背压对注塑工艺的影响

通过背压对不同类型塑料注塑工艺的影响试验,指出在一般注射成型背压压力范围内,背压压力的改变具有压力效应和温升效应的双重性,而且两者相互消长,并对传统的背压曲线提出新的见解。传统的背压曲线中塑化量随着背压的增加呈线性下降的关系,而实际生产中,是呈先升后降的关系,且对不同类型塑料的影响也是大小不一,因此在实际注射成型生产中应该慎重地结合其它工艺条件进行背压的调整。