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：单螺杆挤出机无疑是聚合物加工行业中最重要的机器。在塑化挤出过程中，聚合物以固态喂入挤出机，材料在通过旋转挤出机螺杆从进料口输送到模具时熔化。基于经济框架，机器制造商的首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传输现象。该牵头机构研究项目将重点关注实心床破碎螺杆概念，详细研究波分散螺杆。为了加深对波色散螺杆复杂过程的理解，将借助 3D-CFD 模拟开发新的过程模型，并通过在光滑筒 (KTP) 和沟槽筒 (KTP) 上进行的实验研究进行验证。 IPEC）单螺杆挤出机，涵盖了各种可能的挤出工艺。与现有的过程行为简化模型相比，这将提高波色散螺杆的建模精度，从而为波色散螺杆的螺杆优化提供潜力，以便它们能够充分发挥其潜力。假设和方法：3D-CFD-模拟将以两种不同的方式进行。一方面，通过许多熔体主导的弯曲螺杆通道模拟生成数据驱动的压力/吞吐量模型。另一方面，引入了非等温3D-CFD模拟模型，该模型也考虑了固体材料的熔化，并用于不同波色散螺杆的分析。此外，还制定了波色散螺杆上加工的常见材料类型的设计指南。这将有助于满足单螺杆挤出领域对产量和熔体质量的高要求。此外，还将在各种45毫米单螺杆挤出机上进行实验研究，以验证这些模型。 创新性和新颖性：涉及上述主题的几篇科学论文仍然留下了许多未解答的问题，表明该提案的内容具有高度的准确性。相关的。研究表明，波分散螺杆可以带来更高的产量和更好的熔体均匀性，但设计螺杆的分析计算模型缺乏精度。由于所研究的螺杆概念必须经过精心设计才能发挥其全部优势，因此我们的目标是融合 KTP（帕德博恩）和 IPEC（林茨）在建模和仿真领域的专业知识，以产生新的建模方法，从而大大提高预测的准确性。因此，波分散螺杆的成功且值得信赖的设计和使用将成为可能。