微纳层叠聚丙烯腈凝胶流动特性的数值模拟研究

建立了层叠流道的三维模型和有限元网格模型，根据流变测试数据，采用Polymat对物料的黏度模型参数进行拟合，并利用Polyflow软件对聚丙烯腈（PAN）凝胶在层叠流道内的三维等温流动过程进行了数值模拟分析。研究发现，当入口流量增大时，层叠流道出口速度的不均匀性增加；沿流动方向流道内压力逐渐降低，并在出口处降低至同一最低值；流道进出口压力差与入口流量大小具有正相关性；在流道的中心截面上剪切速率分布均匀，波动较小。     

三层共挤出吹膜机头流道的流场分析

三层共挤吹塑薄膜可将产品的多种特性在挤出过程中进行复合,并能大幅度地降低成本,因而其应用越来越广泛。以LDPE/HDPE/LDPE三层共挤出薄膜为例,确定了三层共挤吹膜机头的流道结构,使用ICEM CFD对机头流道划分全六面体网格,采用POLYFLOW对机头流道内等温流动过程进行求解并分析了压力场、速度场和剪切速率场。机头流道流场的研究结果表明,层分配流道压力降较高,共挤出流道压力降较低;层分配流道存在滞留区,熔体汇入共挤出流道后,相邻层熔体的速度分布向该层速度分布方式不断变化;层分配流道中,沿螺旋槽轴线方向,剪切速率逐渐降低,随着层数的增加,共挤出流道壁面上的剪切速率减小。     

啮合同向双螺杆挤出机滑移条件下的仿真分析

双螺杆挤出中的壁面滑移现象在加工过程中具有重要作用,为了探索壁面滑移对流道内物料的影响,利用流体仿真软件Polyflow对螺杆壁面滑移条件下流道内的三维流场作了数值模拟,得出了流道内的压力、速度、剪切速率及黏度的分布。随着最大滑移应力数值的增大,滑移现象消失,流道内的速度场、剪切速率及黏度均受流道几何形状影响,数值波动较大。研究结果表明,壁面滑移条件的产生有利于获得一个较高且稳定的黏度值,提高啮合型同向双螺杆挤出机流率的稳定性,可以有效延长螺杆使用寿命。     

L型宽幅挤出机头挤出稳定性研究

通过ANSYS软件对L型宽幅挤出机头流道三维非等温流场进行数值模拟,分析高分子物料在非等温挤出过程中的流场规律,探讨机头流道壁面温度、进料口压力、阻尼宽度和阻尼高度等参数对机头流道内物料流动的影响规律。结果表明:阻尼宽度对物料具有明显的调压作用;机头流道参数对物料挤出压力和挤出均匀性的影响趋势不同,当壁面温度为338～343 K、进料口压力为15.0～19.6 MPa、阻尼宽度为8 mm、阻尼高度为3 mm时,物料挤出均匀性和稳定性较好,可实现高分子片材挤出质量和挤出产量的平衡。     

对顶式内衬层生产线挤出机机头流道优化分析

采用Ansys-polyflow软件对对顶式内衬层生产线挤出机机头流道流场进行优化分析。机头流道结构直接影响挤出出口断面宽度方向胶料流速、温度、压力和剪切速率分布的均匀性。减小机头流道中部区域的阻尼,可有效解决半成品中间壁厚偏小和两边壁厚偏大的问题;增大机头流道分散角有助于优化胶料流动,有效减小出口断面宽度方向不同部位胶料流速、压力、温度和剪切速率差值。优化设计挤出机机头流道呈鱼尾状,流经流道的胶料呈压缩式层流流动,基本实现了出口断面宽度方向胶料流速、压力、温度和剪切速率分布均匀。     

基于有限元的流道出口胶料速率均匀性分析

胶料熔体在流道出口沿宽度方向上速率的均匀性是保证挤出制品品质的重要因素,在已优化的流道结构基础上研究胶料在流道出口速率均匀性的影响因素。利用Fluent流体动力学软件进行模拟,改变工艺参数,分析速度场、应力场、压力场的分布。结果表明,胎面胶料黏度减小或入口压力增大均会引起流道出口中间的速率偏大;而温度的改变对流道出口速率均匀性影响不明显。     

PP/EPDM/玻璃微珠复合材料挤出流动中粘弹特性的研究

采用恒速率型毛细管流变仪，考察190℃下PP／EPDM／玻璃微珠复合材料挤出流动中的粘弹特性．结果表明，复合材料挤出流动中的入口压力降随着流道壁面剪切应力的增大而增大，拉仲粘度随着入口压力降的增大而提高，挤出胀大比随着流道壁面剪切应力的增大而增大，随着玻璃微珠含量的增大而减小，玻璃微珠含量在一定范围内，采用马来酸酐接枝EPDM及表面改性(用硅烷偶联剂)玻璃微珠的复合材料挤出胀大比较大。     

高分子材料动态成型过程中熔体非线性行为的研究

借助流变测量和连续介质理论,不依赖已有的本构关系,对平行叠加正弦振动条件下高分子熔体经毛细管的动态挤出过程进行了理论分析。以低密度聚乙烯(LDPE)为原材料,实验测量LDPE熔体在一定振动频率和振幅下毛细管入口压力、体积流量和挤出胀大的瞬态值,即可得到动态成型过程中高分子熔体剪切应力、剪切速率和表观粘度的变化规律:随振幅和频率的变化,LDPE熔体的表观粘度呈非线性变化趋势;在不同的振幅和频率下动态挤出LDPE熔体,跟稳态挤出时一样,壁面剪切应力与壁面剪切速率也成非线性比例关系。     

微纳层叠天然橡胶/聚丙烯两相挤出的数值模拟研究

为了确保天然橡胶/聚丙烯（NR/PP）通过微纳层叠挤出的厚度均匀，建立了三维模型层叠流道，根据流变测试结果拟合材料黏度，并对NR/PP三维等温黏弹性流动进行了数值模拟。结果表明，当2种物料的入口流动速率相同时，流道出口处两相速度有突变，不同流道之间速度差较大，两相黏度分界不明晰，界面出现一定程度的相互渗入；调整两相的入口流动速率后，速度过渡平稳，不同流道间速度差减小，黏度分界规整，界面无偏移现象。     

两端进料式宽幅片材挤出机头流道流场分析

建立两端进料式宽幅片材挤出机头流道三维几何模型,并对物料在流道内的流动进行数值模拟.模拟结果表明,流道内部压力在沿挤出方向递减的同时逐渐趋于横向均匀.高度分别为5和8 mm的阻尼部分对比分析表明,适当调整阻尼部分高度,可影响出口区域挤出速度横向分布,使横向挤出压力和速度更均匀.     

衣架式模头设计理论及其流道数值模拟验证

按照微元法进行数学建模,以非牛顿流体在歧路管中的全展流动模型和在狭缝流道中的全展流动模型为理论基础,应用所有流径上压力降相等和歧路管内外壁剪切速率相等的设计准则,实现沿模头幅宽方向的流量分布均匀设计目标,并用Pro/E进行参数化建模和几何模型网格划分,最后采用Polyflow有限元软件对理论设计进行数值模拟验证,得到压力分布、速度场和壁面剪切速率.模拟结果表明:压力降符合较好,均匀性在宽幅方向上基本一致,剪切速率与设计准则相符.     

The flow of polymer melts through the clearance over a barrier flight in extruders

The flow of polymer melts through the clearance over a barrier flight in extruders involves high, rapidly changing shear rates. Polymer melts, being viscoelastic, are expected to exhibit a high elasticity when they flow through the clearance, so the flow through the clearance may not be predictable or stable. The flow through the clearance over a barrier flight was investigated using a shear refining (SR) module connected to an extruder. Three polymers with different melt properties were tested: branched low density polyethylene (BLDPE), high‐density polyethylene (HDPE), and polystyrene (PS). The measured drag flow rate through the clearance was found to be equal to the prediction for a purely viscous fluid, which gives a linear velocity profile in the clearance. At the threshold rotor speed of the SR module whereupon the predicted drag flow rate through the clearance is the same as the extruder output rate, the melt pressures at the inlet and the outlet of the SR module were nearly equal and stable. Below the threshold rotor speed, the inlet pressure was higher than the outlet pressure. Above the threshold rotor speed, the inlet pressure was nearly zero and the outlet pressure fluctuated. The magnitude of the pressure fluctuation increased with increasing rotor speed and decreased with increasing melt temperature. HDPE, which had a higher melt elasticity, showed more pressure fluctuation than BLDPE and PS. The pressure fluctuation probably results from the flow instability through the clearance caused by the melt elasticity.     

A study of melt density of flowing linear polyethylene

Linear polyethylene was extruded from a capillary rheometer with the driving piston operated at fixed speed and at fixed pressure. Apparent viscosity and melt density were measured in both extrusion modes. Apparent density decreased at shear rates approaching the melt fracture region in fixed piston-speed operation. Flow of other polymer melts was essentially incompressible in fixed piston-speed operation, and all polymers exhibited incompressible flow in fixed-pressure extrusion. The oscillating portion of the flow curve of linear polyethylene reflects alternating periods in which the polymer exits faster and slower than the rate at which the advancing piston clears the rheometer reservoir. Linear polyethylene behaves differently from most other polymers in fixed piston-speed extrusion and during melt fracture because of the existence of a more extensive entanglement network in the melt. It is suggested that melt fracture in general results from a tensile failure of the entanglement network, which may occur at the die inlet and in the orifice.     

管壁厚度对微挤出成型的影响分析

基于Bird-Carreau黏度模型,运用有限元方法对三维等温微管挤出成型流动模型进行了数值分析,主要研究了管壁厚度对微管挤出成型过程中挤出胀大、速度分布、剪切速率和口模压降等重要指标的影响。结果表明,当熔体入口体积流率相等时,随着管壁厚度的增大,挤出物挤出胀大率和横截面尺寸变化量增大;口模出口端面上熔体的二次流动增强,但挤出速度和剪切速率减小;熔体在口模内的压力降明显下降;适当增加管壁厚度,有利于提高微管挤出质量。     

芯棒式管材挤出机头的流动模拟分析

以实测高密度聚乙烯(HDPE)的性能参数为基础,提出了以挤出口模壁面附近的剪切速率、壁面附近的熔体流动速度与管中心熔体流动速度之比值来描述速度变化、用压力梯度描述压力变化的观点,采用Ansys、Matlab软件对芯棒式管材机头中挤出HDPE薄壁管的成型过程进行了模拟,并系统地描述、分析了成型段的长度及入口压力、入口速度发生变化时对成型段上的速度分布和压力分布的影响,得到了成型段长厚比与入口压力的优化值。     

A study on the performance of the maddock mixing head in plasticating single-screw extrusion

An experimental and theoretical study was conducted on the performance of the Maddock mixing head in plasticating single-screw extrusion. For the experimental study, a low-density polyethylene was extruded in an extruder that had nine pressure transducers mounted, almost equally spaced along the extruder axis, on the wall of the extruder barrel. Two screws with the Maddock mixing head were used, namely: one screw to measure the pressure difference between the entrance and the exit of the mixing head in the down-channel direction, and the other screw to measure pressure variations in the cross-channel direction in the middle of the mixing head. Our experimental results showed both pressure decrease and pressure increase in the down-channel direction of the mixing head, depending upon the extrusion conditions employed. Using the flow analysis network (FAN) method, we predicted pressure variations in both the downchannel and cross-channel directions of the Maddock mixing head, which agree with experimental results.     

Electrodiffusion diagnostics of the flow and mass transfer inside a network of crossing minichannels

The global mass transfer and the local flow structure inside a set of crossing minichannels were characterized using the electrodiffusion method. The individual square-cross channel sections (a = 1.5 mm in sides) intersect at right-angles in order to form the flow cell. An array of 39 circular platinum electrodes (0.25 mm in diameter) was flush-mounted into the wall of the flow cell to investigate the wall shear rate at different locations. This array of small sensors allowed characterization of longitudinal and lateral variations in wall shear rate across the flow cell, flow distribution at the inlet and outlet sections, transition between laminar and turbulent flow regimes, and flow behaviour at the channel crossings. The results of global wall mass transfer measurements demonstrated that, from a mass transfer point of view, the flow cell exhibits similar behaviour to a porous medium.     

陶瓷颗粒堆积床内的流动特性数值模拟分析

针对化工生产过程中需要根据堆积床的流动特性来对反应器进行设计优化,提出了采用离散元素方法(DEM)和计算流体动力学(CFD)耦合方法,研究了不同物料流速下管径-粒径比为6.33(符合高管径-粒径比D/d 4)的堆积床反应器内部流动特性。通过数值模拟空隙率、压降、压力、流速、流线分布规律,并与常用经验方法结果相对比,验证两种方法的相关性、一致性、可靠性以及CFD-DEM方法的优势。研究表明,物料流速最大(0.8 m·s~(-1))时,堆积床内的最大流速增长率最小为1.9%,平均压降增长率最小为40%,增大物料流速能够减小近壁空隙率,减小壁面效应的影响;最大压降为25 Pa,可预测工业生产中存在的其他不利因素;结合实际生产具体情况,适当增加物料流速可达到最优设计效果。     

微肋阵通道内流动沸腾CHF特性

以去离子水为工质,在质量流速G为96～224 kg·m^-2·s^-1,入口过冷度为20～50℃,有效热通量为10～240 W·cm^-2的范围内,对圆形、菱形、椭圆形微肋阵通道内流动沸腾临界热通量（critical heat flux,CHF）特性进行了实验研究。临界热通量是通道出口壁面干涸造成的,而出口壁面的干涸是由于流动沸腾向通道上游的反向流动。出口壁温的剧增和两相压降的剧减标志着CHF的发生。此外研究发现质量流速、入口过冷度、微肋形状等实验参数对CHF也有着很大的影响。实验结果表明：在相同的实验工况条件下,微肋片的存在大大减小了沸腾的反向流动和流动沸腾的不稳定性,微肋阵通道的CHF比光滑微通道更高,且椭圆形微肋阵的CHF最大,菱形微肋阵次之,圆形微肋阵最小;CHF随着质量流速和入口过冷度的增大而增大,但随着出口干度的增大而减小。最后将实验数据文献中的关联式进行了比较验证,结果表明该实验数据与关联式吻合良好。