Design and Optimization of Wave-Dispersion Screws

消波螺杆的设计与优化

• 批准号: 442260345
• 负责人: Professor Dr.-Ing. Volker Schöppner
• 金额: --
• 依托单位: Fachgebiet Kunststoffverarbeitung
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/442260345?language=en
• 关键词: Design; Optimization; Wave; Dispersion; Screws

Content: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 lead-agency research project will investigate wave-dispersion screws in detail. To increase the understanding for the complex processes in wave-dispersion screws, new process models will be developed with the help of 3D-CFD-Simulations and validated by experimental studies carried out on smooth-barrel (KTP) as well as grooved-barrel (IPEC) single screw extruders, covering a wide range on possible extrusion processes. This will increase the modeling accuracy of wave-dispersion screws in comparison to existing simplified models of the process behavior and thus give potential for screw optimization of wave-dispersion screws so that they can exploit their full potential.Hypothesis and methods:3D-CFD-Simulations will be carried out in two different ways. On the one hand, a data driven pressure/throughput model is generated by means of many melt-dominated curved screw channel simulations. On the other hand, a non-isothermal 3D-CFD simulation model, which also considers the melting of the solid material, is introduced and used for the analysis of the different wave-dispersion screws. Furthermore, design guidelines for common material types processed on wave-dispersion screws are developed. This will help to meet the high demands in terms of output capacity and melt quality in the field of single-screw extrusion. Additionally, experimental studies will be carried out on various 45mm single-screw extruders to validate these models.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. It has been shown, that wave-dispersion screws can lead to higher throughput and better melt homogeneity, but the analytical calculation models for designing a screw have a lack of precision. Since the investigated screw concept must be meticulously designed in order to unfold its full advantages, the aim is to merge the expertise in the field of modeling and simulation of the KTP, Paderborn and the IPEC, Linz to produce new modeling approaches that considerably increase the accuracy of the predictions. As a result, a successful and trustful design and use of the wave-dispersion screws will be possible.

内容：无疑是聚合物加工行业中最重要的机器。在塑料挤出过程中，将聚合物馈送到固态中的挤出机中，并在材料通过旋转挤出机螺钉从进料端口传输到模具时熔化。基于经济框架，机器制造商的主要目标是提高产量能力，同时确保高融化质量。满足这些需求需要适当的螺丝设计，从而对挤压过程的运输现象有透彻的了解。该铅机构研究项目专注于固定床破坏螺钉概念，将详细研究波浪螺旋螺钉。为了提高对波散发螺钉中复杂过程的理解，将在3D-CFD仿真的帮助下开发新的过程模型，并通过对平滑桶（KTP）进行的实验研究验证，并进行了沟槽（IPEC）单螺钉，从而在可能的挤出过程上覆盖了广泛的范围。与现有过程行为的现有简化模型相比，这将提高波散发螺钉的建模准确性，从而赋予波散发螺钉的螺钉优化螺钉的潜力，从而可以利用其全部潜力和方法：3D-CFD模拟将以两种不同的方式进行。一方面，通过许多融化为主导的曲线螺丝通道模拟，生成数据驱动的压力/吞吐量模型。另一方面，引入并用于分析不同波浪分散螺钉的分析，该模型也考虑了固体材料的熔化模型。此外，还制定了在波散发螺钉上处理的常见材料类型的设计指南。这将有助于满足单螺旋挤压领域的产量和融化质量的高需求。此外，将对各种45毫米单螺钉挤出机进行实验研究以验证这些模型。注射和新颖性：涉及上述主题的少数科学论文仍然留下许多问题，并表明该提案的内容非常相关。已经表明，波散发螺钉可以导致更高的吞吐量和更好的熔融均匀性，但是设计螺钉的分析计算模型缺乏精度。由于必须精心设计研究的螺丝概念以展现其全部优势，因此目的是合并KTP，Paderborn和Ipec的模型和模拟领域的专业知识，以产生新的建模方法，以大大提高预测的准确性。结果，将有可能获得成功而值得信赖的设计和使用螺钉的使用。