New Wave-Screw Concepts in High-Speed Extruder.

研究项目内容：单螺杆挤出机无疑是聚合物加工行业中最重要的设备。在塑化挤出过程中，聚合物在固态状态下被送入挤出机，当材料通过旋转的挤出机螺杆从进料口输送到模具时被熔化。根据经济框架，机械制造商的主要目标是在保证高熔体质量的同时提高产量。满足这些要求需要适当的螺杆设计，从而彻底了解控制挤出过程的输送现象。本研究项目将围绕固体床破碎螺杆的概念，对波和能量传递截面进行详细的研究，特别是它们在高速单螺杆挤出机熔融区中的应用。为了充分利用它们将高产量和优良熔体质量结合在一起的巨大潜力，将开发基于数学-物理模型的新设计策略，并通过在快速运转的单螺杆挤出机上进行的实验研究来验证。这将为结合固体床破碎螺杆截面的高速挤出概念的发展做出可持续的贡献。假设：本研究工作将为优化高速单螺杆挤出机熔融区中的波和能量传递截面提供所需的数学物理过程模型。这将有助于满足对单螺杆挤出机的产量和熔体质量的高要求。方法：在新型螺杆模拟器上进行实验研究，以详细分析固体床破碎流动通道中的熔融过程，并在常规和沟槽喂料高速单螺杆挤出机上进行实验研究。为了扩展现有的过程模型，将采用分析和数值方法，特别是包括网络理论和有限体积方法。创新和新颖性：涉及上述主题的少数几篇科学论文仍然有许多问题没有得到回答，并表明这项提议的内容具有很高的相关性。以前的研究已经证明，在高速挤出过程中，由于固体床早期破碎而导致的产量增加，可以与对熔体质量的高要求相结合。尤其是波和能量传递截面在熔融区的应用引起了人们的高度关注，因为这些区域显示出诱发固体床破裂的潜力。然而，由于波动区或能量传输区通常存在于熔体传送区，它们在熔体传输区的应用需要基于数学物理过程模型的新的设计策略。

Research Project Contents:Single-screw extruders are indisputably the most important machines in the polymer processing industry. During plasticating extrusion, polymer is fed to the extruder in the solid-state and the material is melted as it is conveyed by the rotating extruder screw from the feed port to the die. Based on the economic framework, the primary objective of machine manufacturers is to increase the output capacity while guaranteeing high melt quality. Meeting these demands requires proper screw design and thus a thorough understanding of the transport phenomena governing the extrusion process. Focusing on solid bed breaking screw concepts, this research project will investigate wave- and energy-transfer-sections in detail placing special emphasis on their application in the melting zone of high-speed single-screw extruders. In order to take advantage of their great potential to combine both high output rates and excellent melt quality, new design strategies based on mathematical-physical models will be developed and validated by experimental studies carried out on fast running single-screw extruders. This will yield a sustainable contribution for the development of high-speed extrusion concepts in combination with solid bed breaking screw sections.Hypothesis:The research work will provide mathematical-physical process models needed to optimize wave- and energy-transfer-sections in the melting zone of high-speed single-screw extruders. This will help to meet the high demands made on the single-screw extruder regarding output capacity and melt quality.Methods:Experimental studies will be carried out on both a novel screw simulator allowing the detailed analysis of the melting process in solid bed breaking flow channels and on a conventional as well as a grooved feed high-speed single-screw extruder. To extend existing process models, analytical as well as numerical methods will be applied comprising the network theory and the finite volume method in particular. Innovation and novelty:The few scientific papers dealing with the above mentioned topic still leave many questions unanswered and show that the contents of this proposal are highly relevant. Previous studies have proven that increased output rates caused by an early breaking of the solid bed in high-speed extrusion can be combined with the high requirements in terms of melt quality. Especially the application of wave- and energy-transfer-sections in the melting zone is of high interest, as these zones show the potential to induce solid bed breaking. However, as wave- or energy-transfer-zones are usually found in the melt conveying zone, their application in the melting zone requires new design strategies based on mathematical-physical process models.