双螺杆构型及挤压参数的建模与试验研究
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摘要
螺杆构型是双螺杆挤压机的核心部件,物料在不同的螺杆构型中受到的热机械效能和停留时间分布存在差异,最终影响挤出产品的综合性能。高温脱脂粕因其氮溶解指数NSI<30%,难以实现挤压组织化,由此,相关挤压机理、螺杆构型及其挤压参数的研究鲜见报道。本文基于高温脱脂粕双螺杆挤压组织化关键技术研究背景,对螺杆构型的数学建模、高温脱脂粕粉在螺杆构型全流道内的流动机理、螺杆构型及其挤压参数对组织化蛋白目标参数的影响进行研究,并取得了重要研究成果。
1)根据全啮合同向双螺杆的啮合原理,建立了螺杆构型的全局数学模型,并据此建立了螺杆构型的理论设计方法。
2)以高温脱脂粕为原料,TXLL110型同向啮合双螺杆挤压机为设备,以螺杆构型为试验因素,设计3种螺杆构型并进行比较试验,通过试验分析得出,螺杆构型对高温脱脂粕挤压组织化目标参数的主要影响因素是熔融区长径比与螺杆元件组合。
3)通过对螺杆构型全流道内压力场、速度场、温度场的数值模拟与分析得出：输送区应采用大螺距正向螺纹输送元件以获得较大的加料能力,输送区的压力、温度变化较小,压力变化范围0～1MPa,温度变化范围80～84℃；熔融区应设置正反向捏合块及开槽螺纹元件,并且与其上游的螺纹元件按一定压缩比有效组合起来。熔融区的压力、温度逐渐上升,压力变化范围0.9-3.0MPa,温度变化范围95～153℃；计量均化区应配置中小螺距双头螺纹元件,计量均化区压力、温度变化很小,压力基本在3.0-3.4MPa范围内,温度基本在155～157℃范围内。
4)通过响应面试验与回归分析,得到螺杆长径比、熔融区长径比、模口直径与挤压产品组织化度,以及螺杆长径比、熔融区长径比、模口直径与挤压产品感官评定的数学模型,为螺杆结构设计提供了理论依据,同时,通过响应优化得到结构参数的较优取值：螺杆长径比25.5：1,熔融区长径比12：1,模口直径16mm。
5)通过响应面试验与回归分析,得到机筒温度、物料含水率、喂料速度、螺杆转速与挤压产品组织化度,以及机筒温度、物料含水率、喂料速度、螺杆转速与挤压产品感官评定的数学模型,为挤压过程控制提供了理论依据,同时,通过响应优化得到操作参数的较优取值：机筒温度145～147℃,物料含水率30%,喂料速度550～560kg/h,螺杆转速340r/min。本文的研究成果开创了高温脱脂粕挤压组织化研究的新领域,为双螺杆挤压机的设计制造、挤压工艺的制定提供了理论依据。
The screw configuration is the main component in a twin-screw extruder. Because the raw material is subjected to different thermal mechanical efficiency and residence time distribution in different screw configuration, so lead to different product performance. Because nitrogen solubility index NSI<30%, so it is difficult to achieve high-temperature defatted meal extrusion texturization, and the less study has been reported on extrusion mechanism, screw configuration and extrusion parameters. This article is based on the technology of high-temperature defatted meal extrusion texturization, then, the author studied mathematical model of screw configurations, flow mechanism of material flow in whole runner and the influence of screw configurations and extrusion parameters on target parameters of products, at the same time, achieved important research results.
1) According to the meshing principle of intermeshing co-rotating twin screw, the mathematical model and design method of the whole screw configuration were built up.
2) Using high-temperature defatted peanut meal as raw material, using TXLL110twin-screw extruder, the influence of three kinds of screw configurations on target parameters of products was studied by comparison experiment. The results showed that the ration between length and diameter of molten area and screw element combination were the main factors.
3) The results of numerical simulation showed that coarse pitch single thread screw element could be used in feeding zone. Pressure range0-1MPa, temperature range80-84℃; Forward and reverse kneading block and slotted screw element could be used in melting zone. Pressure range0.9-3.0MPa, temperature range95-153℃; Small and medium pitch double thread screw element could be used in homogenizing zone. Pressure range3.0-3.4MPa, temperature range155-157℃.
4) The mathematical models of structure parameters and target parameters were obtained by response surface analysis. The products obtained the optimum structure under the conditions of the ration between length and diameter of screw25.5:1, the ration between length and diameter of molten area12:1, and the diameter of die orifice16mm.
5) The mathematical models of process parameters and target parameters were obtained by response surface analysis. The products obtained the optimum structure under the conditions of barrel temperature (zone4)145-147℃, feed moisture30%, feed speed550-560kg/h, and screw speed340r/min. As theoretical basis, the results could be used in the design and study of twin-screw extruder on high-temperature defatted meal extrusion texturization.
1)根据全啮合同向双螺杆的啮合原理,建立了螺杆构型的全局数学模型,并据此建立了螺杆构型的理论设计方法。
2)以高温脱脂粕为原料,TXLL110型同向啮合双螺杆挤压机为设备,以螺杆构型为试验因素,设计3种螺杆构型并进行比较试验,通过试验分析得出,螺杆构型对高温脱脂粕挤压组织化目标参数的主要影响因素是熔融区长径比与螺杆元件组合。
3)通过对螺杆构型全流道内压力场、速度场、温度场的数值模拟与分析得出：输送区应采用大螺距正向螺纹输送元件以获得较大的加料能力,输送区的压力、温度变化较小,压力变化范围0～1MPa,温度变化范围80～84℃；熔融区应设置正反向捏合块及开槽螺纹元件,并且与其上游的螺纹元件按一定压缩比有效组合起来。熔融区的压力、温度逐渐上升,压力变化范围0.9-3.0MPa,温度变化范围95～153℃；计量均化区应配置中小螺距双头螺纹元件,计量均化区压力、温度变化很小,压力基本在3.0-3.4MPa范围内,温度基本在155～157℃范围内。
4)通过响应面试验与回归分析,得到螺杆长径比、熔融区长径比、模口直径与挤压产品组织化度,以及螺杆长径比、熔融区长径比、模口直径与挤压产品感官评定的数学模型,为螺杆结构设计提供了理论依据,同时,通过响应优化得到结构参数的较优取值：螺杆长径比25.5：1,熔融区长径比12：1,模口直径16mm。
5)通过响应面试验与回归分析,得到机筒温度、物料含水率、喂料速度、螺杆转速与挤压产品组织化度,以及机筒温度、物料含水率、喂料速度、螺杆转速与挤压产品感官评定的数学模型,为挤压过程控制提供了理论依据,同时,通过响应优化得到操作参数的较优取值：机筒温度145～147℃,物料含水率30%,喂料速度550～560kg/h,螺杆转速340r/min。本文的研究成果开创了高温脱脂粕挤压组织化研究的新领域,为双螺杆挤压机的设计制造、挤压工艺的制定提供了理论依据。
The screw configuration is the main component in a twin-screw extruder. Because the raw material is subjected to different thermal mechanical efficiency and residence time distribution in different screw configuration, so lead to different product performance. Because nitrogen solubility index NSI<30%, so it is difficult to achieve high-temperature defatted meal extrusion texturization, and the less study has been reported on extrusion mechanism, screw configuration and extrusion parameters. This article is based on the technology of high-temperature defatted meal extrusion texturization, then, the author studied mathematical model of screw configurations, flow mechanism of material flow in whole runner and the influence of screw configurations and extrusion parameters on target parameters of products, at the same time, achieved important research results.
1) According to the meshing principle of intermeshing co-rotating twin screw, the mathematical model and design method of the whole screw configuration were built up.
2) Using high-temperature defatted peanut meal as raw material, using TXLL110twin-screw extruder, the influence of three kinds of screw configurations on target parameters of products was studied by comparison experiment. The results showed that the ration between length and diameter of molten area and screw element combination were the main factors.
3) The results of numerical simulation showed that coarse pitch single thread screw element could be used in feeding zone. Pressure range0-1MPa, temperature range80-84℃; Forward and reverse kneading block and slotted screw element could be used in melting zone. Pressure range0.9-3.0MPa, temperature range95-153℃; Small and medium pitch double thread screw element could be used in homogenizing zone. Pressure range3.0-3.4MPa, temperature range155-157℃.
4) The mathematical models of structure parameters and target parameters were obtained by response surface analysis. The products obtained the optimum structure under the conditions of the ration between length and diameter of screw25.5:1, the ration between length and diameter of molten area12:1, and the diameter of die orifice16mm.
5) The mathematical models of process parameters and target parameters were obtained by response surface analysis. The products obtained the optimum structure under the conditions of barrel temperature (zone4)145-147℃, feed moisture30%, feed speed550-560kg/h, and screw speed340r/min. As theoretical basis, the results could be used in the design and study of twin-screw extruder on high-temperature defatted meal extrusion texturization.
引文
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