Active driving pulse deformation forming method and equipment for ultrahigh molecular weight polymer pipe
Technical Field
The invention relates to the technical field of high polymer material extrusion processing, in particular to an active drive pulse deformation forming method and equipment for an ultrahigh molecular weight polymer pipe.
Background
The ultra-high molecular weight polymer has extremely high molecular weight, so that the ultra-high molecular weight polymer product has excellent performance which is not possessed by common high molecular materials. For example, the ultra-high molecular weight polyethylene resin product has high mechanical strength, excellent wear resistance, light weight, environmental protection and low water absorption, and is widely applied to the fields of textile, papermaking, food machinery, transportation, metallurgy, coal and the like; the PMMA (polymethyl methacrylate) with the ultra-high molecular weight can also keep the mechanical strength at the high temperature of more than 200 ℃, and also has strong toughness, wear resistance and impact resistance; the polytetrafluoroethylene, which is called "plastic king", has the characteristics of high temperature resistance and extremely low friction coefficient.
However, the ultra-high molecular weight polymer has a low critical shear rate, and is liable to melt fracture at a very low rotation speed, and the surface of the product is uneven, so that the production efficiency is low. The friction coefficient of the material is small, and the feeding section is easy to slip, so that the material cannot be pushed forwards along the axial direction, and the extrusion is easy to be unstable; meanwhile, the melt has high viscosity, high elasticity, small diffusion degree among molecular chains, long relaxation time and easy generation of weld marks.
The traditional forming process of the ultra-high molecular weight polymer pipe comprises a solid extrusion method, a hard top method, a welding method, a bonding method, a winding method and the like. The pipe obtained by the hard top forming method has high welding strength, but the extrusion speed is extremely slow; when the extrusion speed is increased, the problem of welding marks is obvious because the welding between different material flows is poor in the pipe die head, internal defects are easily caused, and meanwhile, the surface quality of the pipe is difficult to control. The traditional winding pipe is wound in a section cooling state and is bonded into a whole by hot melt plastics, so that the welding strength of the splicing part of the winding pipe is low. The strength of the weld formed by welding or bonding is less than 50% of the original strength, and the weld is liable to break and leak, and thus cannot meet industrial requirements.
Therefore, aiming at the problems existing in the forming of the existing ultra-high molecular weight polymer pipe, the method and the equipment for forming the ultra-high molecular weight polymer pipe are developed, have high production efficiency, small internal stress, high welding strength of different material flows and no welding mark, and have important significance for further developing and utilizing a plurality of excellent properties of the ultra-high molecular weight polymer material.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides an active driving pulse deformation forming method for an ultrahigh molecular weight polymer pipe, which can effectively improve the production efficiency of pipe forming on the premise of ensuring higher welding strength.
The invention also aims to provide the ultrahigh molecular weight polymer pipe active drive pulsating deformation forming equipment for realizing the method.
The technical scheme of the invention is as follows: an active drive pulse deformation forming method for an ultrahigh molecular weight polymer pipe comprises the steps of firstly plasticizing and extruding an ultrahigh molecular weight polymer raw material by using an extruder main machine, preforming the raw material into a sheet material, and then feeding the sheet material into a pipe forming auxiliary machine to be wound and formed into the pipe;
the pipe forming auxiliary machine comprises a machine barrel and a mandrel arranged in the machine barrel, grooves are distributed on the inner wall of the machine barrel, the driving mode of the mandrel adopts active driving (namely the mandrel of a forming die is driven by a motor), a cavity with the volume changing periodically in a pulsating mode is formed between the machine barrel and the mandrel, and a melt formed after a sheet is wound is compressed and expanded in the cavity in the conveying process, so that the diffusion, welding and internal stress release of polymer macromolecular chains are promoted, the welding strength among different material flows of the formed pipe is ensured, and welding marks are avoided.
When the sheet enters the pipe forming auxiliary machine, an included angle alpha is formed between the center line of the sheet and the center line of the feeding hole of the machine barrel, and
in the formula D
b The diameter of the cylinder, W is the width of the sheet. The included angle is set, so that the sheet can be wound on a mandrel of the pipe forming auxiliary machine and can be spliced seamlessly.
In the process that the melt formed after the sheet is melted is conveyed in the cavity, the periphery of the machine barrel is also provided with a first heater, and the diffusion, welding and internal stress release of the macromolecular chains of the polymer are further promoted under the auxiliary action of external heating of the first heater. In addition, after the pipe is formed and sent out of the pipe forming auxiliary machine, the pipe can be sequentially cooled, formed and cut by adopting a cooling mechanism and a cutting mechanism, and finally a standard pipe product is obtained.
The invention relates to an ultrahigh molecular weight polymer pipe active drive pulsating deformation forming device, which comprises an extruder main machine and a pipe forming auxiliary machine which are connected, wherein the pipe forming auxiliary machine comprises a machine barrel and a mandrel arranged in the machine barrel, and grooves are distributed on the inner wall of the machine barrel; a feed port is arranged on the side wall of one end of the machine barrel and is connected with the extruder main machine, a discharge port is arranged at the other end of the machine barrel, and the discharge port is also connected with a die barrel; the dabber is including the axis body and the spindle nose that are connected, and the axis body is located the barrel, and the spindle nose is located a mould section of thick bamboo. The feeding port is a rectangular through hole formed in the side wall of the machine barrel, and sheets molded by the extruder main machine directly enter the pipe molding auxiliary machine from the feeding port; all grooves (the groove structure can be axial grooves or spiral grooves) on the inner wall of the machine barrel are uniformly distributed on the inner wall of the machine barrel along the circumferential direction of the machine barrel; the mandrel is an actively-driven rotary mandrel, can provide driving force, enables the mandrel to rotate to drive materials to advance, ensures that the forming flow resistance is reduced under the forming condition with long residence time, and avoids the problems of high energy consumption and overlarge axial pressure caused by large length of the die head.
The shaft head comprises a gradual change section and a flat section which are connected, two ends of the gradual change section are respectively connected with the shaft body and the flat section, and the diameter of the gradual change section is gradually reduced along the extrusion direction. That is to say, on the dabber, the diameter of straight section is less than the diameter of axis body, and carries out transition connection through the transition section between the two. The spindle head is made of wear-resistant materials or is subjected to surface heat treatment, coating, infiltration layer and other technologies to improve the wear resistance and relieve the problem of product size deviation caused by serious surface wear due to friction between the spindle and the materials.
The inner wall shape of the mouth die cylinder is the same as that of the shaft head, a wear-resistant lining is further arranged between the mouth die cylinder and the shaft head, the outer wall of the wear-resistant lining is in contact with the inner wall of the mouth die cylinder, and the shape of the wear-resistant lining is also the same as that of the shaft head. The wear-resistant bush is provided with an inlet and an outlet which are communicated with the machine barrel, the inlet of the bush is communicated with a discharge hole of the machine barrel, a forming cavity is formed between the wear-resistant bush and the shaft head, and the forming cavity is sequentially provided with a corresponding gradual change section and a flat section along the direction from the inlet to the outlet, so that stable extrusion of the pipe and size adjustment of products are realized.
Preferably, an inclined edge is arranged at one end, corresponding to the feeding port on the machine barrel, of the outer cylindrical surface of the shaft body. In addition, other parts on the mandrel are optical axes, the structure of the mandrel is relatively complex, but after the sheet enters the feeding hole, the oblique edges can generate an occlusion effect on the sheet, the sheet is wound on the mandrel at a certain angle under the occlusion effect of the oblique edges, a cavity with a pulsating volume change is formed between the mandrel and the machine barrel, the melt is subjected to the compression and expansion effect of the pulsating volume change, and under the auxiliary effect of external heating, the diffusion and the relaxation of macromolecular chains and the release of internal stress are promoted, so that the weld marks are effectively eliminated.
As another preferable scheme, the axis body is an optical axis. Namely, the outer cylindrical surface of the shaft body is a smooth surface and is not provided with any inclined edge or curved surface. The shaft body is simple in structure, simple and convenient to process, high in adaptability and free of shearing effect on materials, and the engagement effect on sheets is not as good as that of the shaft body with the inclined edges.
An included angle alpha is formed between the extruder main machine and the pipe forming auxiliary machine, and
in the formula D
b The diameter of the cylinder, W is the width of the sheet. The included angle formed between the extruder main machine and the pipe forming auxiliary machine is the included angle formed between the central line of the sheet and the central line of the feeding hole of the machine barrel, and the sheet can be wound on the mandrel of the pipe forming auxiliary machine and spliced seamlessly.
The periphery of the cylinder is provided with a first heater, and the periphery of the neck mold cylinder is provided with a second heater. In addition, a first temperature sensor is further arranged on the machine barrel, a second temperature sensor is further arranged on the die barrel, the temperatures of the melts in the machine barrel and the die barrel are detected in real time through the first temperature sensor and the second temperature sensor, and are fed back to a controller of the equipment, so that the heating temperatures of the first heater and the second heater can be adjusted in real time, and the temperature of the melt is kept constant.
Besides the structure, the pipe forming auxiliary machine further comprises a cooling mechanism, a cutting mechanism, a carrier roller supporting mechanism and a driving mechanism. Wherein, cooling mechanism includes sizing cover and basin, and the export of a mouthful mould section of thick bamboo is connected with sizing cover, basin in proper order. The carrier roller supporting mechanism comprises a carrier roller and a carrier roller supporting frame, the carrier roller is arranged below the pipe at the outlet of the sizing sleeve, and the carrier roller supporting frame is used for arranging the carrier roller. Along extruding direction, cutting mechanism locates the rear of bearing roller supporting mechanism, carries out automatic cutout to the tubular product, realizes assembly line operation, and is efficient, obtains the tubular product that the terminal surface is neat, bright and clean and fixed length. The driving mechanism comprises a motor and a coupler, the motor is connected with the mandrel through the coupler, and the mandrel is driven to rotate.
Compared with the prior art, the invention has the following beneficial effects:
in the active drive pulsating deformation forming method and the equipment for the ultra-high molecular weight polymer pipe, the sheet is extruded by the extruder host, and then the sheet is supplied to the pipe forming auxiliary machine, so that the backpressure of the extruder host can be reduced, the size of the extruder host driving mechanism is reduced, and the production efficiency can be effectively improved.
In the active driving pulsating deformation forming method and the equipment for the ultrahigh molecular weight polymer pipe, a sheet is wound on a pipe forming auxiliary machine at a certain angle to be extruded into the pipe, a cavity with periodically changed volume is formed between a core shaft and a machine barrel through a groove arranged on the inner wall of the machine barrel, pulsating compression release is realized, macromolecule diffusion movement is promoted through the auxiliary action of external heating, internal stress is gradually released, and the problem of low welding strength caused by the traditional pipe winding forming method is solved.
In the active drive pulsating deformation forming method and the equipment for the ultra-high molecular weight polymer pipe, the mandrel in the pipe forming auxiliary machine is actively driven, so that the forming flow resistance can be reduced under the forming condition with long residence time, and the problems of high energy consumption and large required axial pressure due to the large length of the die head are solved.
Drawings
Fig. 1 is a schematic structural diagram of the active drive pulse deformation forming equipment for the ultra-high molecular weight polymer pipe.
Fig. 2 is a schematic structural diagram of the pipe forming auxiliary machine in fig. 1.
Fig. 3 is a front view (with a partial cross-sectional view) of the pipe forming auxiliary machine.
Fig. 4 is a plan view of the pipe forming auxiliary machine (with a partial cross-sectional view).
Fig. 5 is a schematic view of the structure of the cylinder of fig. 2.
Fig. 6 is a front view of the barrel (with a partial cross-sectional schematic view).
Fig. 7 is a cross-sectional view a-a of fig. 6.
Fig. 8 is a schematic structural view of a mandrel in example 1.
Fig. 9 is a schematic structural view of a mandrel in example 2.
Detailed Description
The present invention will be described in further detail with reference to examples, but the embodiments of the present invention are not limited thereto.
Example 1
The active-drive pulsating deformation forming device for the ultra-high molecular weight polymer pipe in the embodiment comprises a main extruder 80 (one end of the main extruder is provided with a control box 90) and a pipe forming auxiliary machine 70 which are connected with each other as shown in fig. 1, wherein the pipe forming auxiliary machine comprises a machine barrel 1 and a mandrel 2 arranged in the machine barrel as shown in fig. 2 to 4, and grooves 1-1 are distributed on the inner wall of the machine barrel as shown in fig. 5 to 7; a feed inlet 1-2 is arranged on the side wall of one end of the machine barrel, the feed inlet is connected with the extruder main machine, a discharge outlet 1-3 is arranged at the other end of the machine barrel, and the discharge outlet is also connected with a die barrel 3 (the end part of the die barrel can also be provided with a baffle ring 4); as shown in fig. 3 or fig. 8, the mandrel comprises a shaft body 2-1 and a shaft head 2-2 which are connected, wherein the shaft body is positioned in the machine barrel, and the shaft head is positioned in the die barrel. The feeding port is a rectangular through hole formed in the side wall of the machine barrel, and sheets molded by the extruder main machine directly enter the pipe molding auxiliary machine from the feeding port; all grooves on the inner wall of the machine barrel are uniformly distributed on the inner wall of the machine barrel along the circumferential direction of the machine barrel; the mandrel is an actively-driven rotary mandrel, provides driving force, enables the mandrel to rotate to drive materials to advance, can reduce forming flow resistance under the forming condition with long residence time, and avoids the problems of high energy consumption and overlarge axial pressure due to large length of the die head.
As shown in FIG. 8, the shaft head comprises a transition section 2-21 and a flat section 2-22 which are connected, two ends of the transition section are respectively connected with the shaft body and the flat section, and the diameter of the transition section is gradually reduced along the extrusion direction. That is to say, on the dabber, the diameter of straight section is less than the diameter of axis body, and carries out transition connection through the transition section between the two. The spindle head is made of wear-resistant materials or is subjected to surface heat treatment, coating, seeping layer and other technologies to improve the wear resistance and relieve the problem of product size deviation caused by serious surface wear due to friction between the spindle and materials.
As shown in fig. 3, the shape of the inner wall of the mouth mold cylinder is the same as that of the shaft head, a wear-resistant bushing 5 is further arranged between the mouth mold cylinder and the shaft head, the outer wall of the wear-resistant bushing is in contact with the inner wall of the mouth mold cylinder, and the shape of the wear-resistant bushing is also the same as that of the shaft head. The wear-resisting bush has the import and the export that communicate with each other with the barrel, and the import of bush communicates with each other with the discharge gate of barrel, forms the molding cavity 6 between wear-resisting bush and the spindle nose, and this molding cavity has set gradually corresponding gradual change section and straight section along the import towards the direction of export in proper order, realizes that tubular product is stably extruded and goods size adjustment.
As shown in figure 4 or figure 8, the outer cylindrical surface of the shaft body is provided with inclined edges 2-11 at one end corresponding to the feeding port on the machine barrel. In addition, other parts on the mandrel are optical axes, the structure of the mandrel is relatively complex, but after the sheet enters the feeding hole, the oblique edges can generate an occlusion effect on the sheet, the sheet is wound on the mandrel at a certain angle under the occlusion effect of the oblique edges, a cavity with a pulsating volume change is formed between the mandrel and the machine barrel, the melt is subjected to the compression and expansion effect of the pulsating volume change, and under the auxiliary effect of external heating, the diffusion and the relaxation of macromolecular chains and the release of internal stress are promoted, so that the weld marks are effectively eliminated.
As shown in figure 1, an included angle alpha is formed between the extruder main machine and the pipe forming auxiliary machine, and
in the formula D
b W is the diameter of the barrel and W is the width of the sheet. The included angle formed between the extruder main machine and the pipe forming auxiliary machine is the included angle formed between the center line of the sheet and the center line of the feeding hole of the machine barrel, and the sheet can be wound on the mandrel of the pipe forming auxiliary machine and can be spliced seamlessly due to the included angle.
As shown in fig. 4, a first heater 7 is provided on the outer periphery of the cylinder, and a second heater 8 is provided on the outer periphery of the die cylinder. In addition, a first temperature sensor 9 is arranged on the machine barrel, a second temperature sensor 10 is arranged on the die cylinder, the temperature of the melt in the machine barrel and the die cylinder is detected in real time through the first temperature sensor and the second temperature sensor, and is fed back to a controller (namely the whole machine control box 90) of the equipment, so that the heating temperature of the first heater and the second heater can be adjusted in real time, and the temperature of the melt is kept constant. The control box 90 is similar to the control box of the existing extruder, the temperature and speed of the whole equipment are adjusted and controlled by the controller, and the controller can realize automatic control by adopting a PLC.
Besides the structure, the pipe forming auxiliary machine further comprises a cooling mechanism, a cutting mechanism, a carrier roller supporting mechanism and a driving mechanism. As shown in fig. 3, the cooling mechanism includes a sizing sleeve 11 and a water tank 12, and the outlet of the die cylinder is connected with the sizing sleeve and the water tank in sequence. The carrier roller supporting mechanism comprises a carrier roller 13 and a carrier roller supporting frame 14, the carrier roller is arranged below the pipe 17 at the outlet of the sizing sleeve, and the carrier roller supporting frame is used for arranging the carrier roller. Along the extrusion direction, a cutting mechanism (not shown in the figure) is arranged behind the carrier roller supporting mechanism to automatically cut the pipe, so that the assembly line operation is realized, the efficiency is high, and the pipe with neat, smooth and fixed length end surface is obtained. The driving mechanism comprises a motor 15 and a coupling 16, wherein the motor is connected with the mandrel through the coupling and drives the mandrel to rotate. The extruder host machine for sheet forming can adopt a common extruder, and can also adopt any mechanism which can continuously plasticize and extrude the ultrahigh molecular weight polymer sheet, such as a general stretching rheological extruder in the market.
In the embodiment, the active driving pulse deformation forming method of the ultrahigh molecular weight polymer pipe can be realized through the equipment, firstly, a host extruder is utilized to plasticize and extrude an ultrahigh molecular weight polymer raw material, the ultrahigh molecular weight polymer raw material is preformed into a sheet material, and then the sheet material is fed into a pipe forming auxiliary machine to be wound and formed into the pipe;
the pipe forming auxiliary machine comprises a machine barrel and a mandrel arranged in the machine barrel, grooves are distributed on the inner wall of the machine barrel, the driving mode of the mandrel adopts active driving (namely the forming die mandrel is driven by a motor), so that a cavity with periodically pulsating volume change is formed between the machine barrel and the mandrel, and a melt formed after a sheet is wound is compressed and expanded by the pulsating change in the process of conveying in the cavity, so that the diffusion, welding and internal stress release of polymer macromolecular chains are promoted, the welding strength of the formed pipe is ensured, and welding marks are avoided.
Wherein, when the sheet enters the pipe forming auxiliary machine, the center line of the sheet and the machine barrelForms an included angle alpha between the central lines of the feeding holes, and
in the formula D
b The diameter of the cylinder, W is the width of the sheet. The included angle is set, so that the sheet can be wound on a mandrel of the pipe forming auxiliary machine and can be spliced seamlessly.
In the process of conveying the melt formed after the sheet material is melted in the cavity, the periphery of the machine barrel is also provided with a first heater, and the diffusion, the welding and the internal stress release of the polymer macromolecular chains are further promoted by the aid of the external heating auxiliary effect of the first heater. In addition, after the pipe is formed and sent out of the pipe forming auxiliary machine, a cooling mechanism and a cutting mechanism can be adopted to sequentially cool, shape and cut the pipe, and finally a standard pipe product is obtained.
Wherein the ultra-high molecular weight polymer is a polymer with a molecular weight of more than one million, such as ultra-high molecular weight polyethylene, polytetrafluoroethylene or ultra-high molecular weight polymethyl methacrylate.
Example 2
Compared with the embodiment 1, the active drive pulsating deformation forming device for the ultra-high molecular weight polymer tube of the embodiment is different in that, as shown in fig. 9, the shaft body is an optical axis. Namely, the outer cylindrical surface of the shaft body is a smooth surface and is not provided with any inclined edge or curved surface. The shaft body is simple in structure, simple and convenient to process, high in adaptability and free of shearing effect on materials, and the engagement effect on sheets is not as good as that of the shaft body with the inclined edges.
As mentioned above, the present invention can be better realized, and the above embodiments are only preferred embodiments of the present invention, and are not intended to limit the scope of the present invention; it is intended that all equivalent variations and modifications made in accordance with the present disclosure be covered by the scope of the present invention as defined in the appended claims.