大容量复合纺丝组件的关键技术研究
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摘要
随着世界化纤工业在制造能力、技术设备、品种开发及产品质量方面的不断进步,进入21世纪,“新合纤”正朝着大容量、超极细的方向发展。我国的化纤产量虽一直位居世界前列,但由于在规模、差别化率等方面的瓶颈制约,产品国际竞争力不强,大容量的纺丝设备国内目前仍然依赖进口。化纤生产中纺丝组件性能的好坏,直接影响到原丝的可纺性和各种性能指标,因此大容量纺丝组件的设计和开发尤为重要。
本论文首先分析了国内外纺丝组件的结构,并对纺丝组件中的分配板和喷丝板进行参数化设计;以流变学基本原理为理论依据,研究高聚物熔体在纺丝组件内的流动机理,建立了熔体在皮芯型喷丝孔中流动的速度数学模型,并用Gambit对皮芯型喷丝孔建立三维模型和网格划分,利用专用CFD软件—Fluent对熔体在其中的流动情况进行了模拟;对大容量皮芯型纺丝组件设计了两套分配板方案,分别对其进行建模、网格划分和熔体流动模拟,通过计算出口的速度不匀率控制在1.5%得出了合理的分配板结构,速度不匀率反映了所纺纤维的条干不匀率,这将为实际实验和生产提供一定的理论依据。
最后,通过模拟所得参数和某公司的设计基础参数设计出一套大容量皮芯型复合纺丝组件,并结合该公司实际生产情况对低熔点棉生产工艺进行研究,取得了良好的效果。
目前国内对纺丝组件的设计大多限于经验,大容量的纺丝组件设计国内还没有报道,本论文最大的意义在于打破了常规组件的设计思路,首次得到皮芯型双组分熔体流动特性的计算模型,并结合如今强大的计算机CAD/CAE功能,基本上实现了在计算机上设计并模拟纺丝,不但节约了实际生产成本又提高了效率,使纺丝组件的设计步入了一个新的阶段。
Entering the 21st century, with the constant progress of the worldwide chemical fiber industry on manufacturing capacity, technical equipment, variety development and product quality, the new synthetic fibers are moving to the direction of large-capacity and ultra-fine. China's chemical fiber production has been the forefront of the highest in the world, but because of the bottleneck restriction on scale, differentiation rate and so on, the product's international competitiveness is not strong, and at present, the large-capacity spinning equipments still rely on imports. The function of spinning component immediately affects the fiber's spinnability and various performance norm. So the design and development of large-capacity spinning component is particularly important. So the design and development of large-capacity spinning component is particularly important.
This dissertation analyzed the structure of large-capacity spinning component, parametric designed for distribution and spinneret of the spinning component. According to basic theory of rheology and spinning technology, discussed rheological behavior of polymer melt when flowing in the large-capacity spinning component. Establishing velocity mathematical model of polymer melt flowing in the sheath-core orifices, then made 3D model and meshed them by Gambit, using the software of CFD-Fluent to simulate polymer melt flowing in the sheath-core orifices to find a reasonable dimension. Designed two sets of distribution system of large-capacity spinning components, made models, meshed and simulated the flowing respectively by Fluent to searching out reasonable distribution system of large-capacity spinning component. Unevenness of velocity was less than 1.5%, Unevenness of velocity expresses the fiber' s Unevenness. This provide theory basis for experiment and production.
Finally, we got the reasonable parameters by the simulation and designed a set of large-capacity sheath-core spinning component with the basic parameters of the company. This provided theoretical guidance for the company in production technology of low-melting point polyester. According to this, achieved some good results.
Spinning components have been designed mostly by experience so far in internal, there has been no report about the designing of large-capacity spinning component until now in internal. This dissertation broke up the routine design method which was the most import. Combing with the powerful CAD/CAE capability of computer we can design spinning component by computer which save not only production cost but also increasing efficiency. So that the design of spinning component will enter a new stage.
本论文首先分析了国内外纺丝组件的结构,并对纺丝组件中的分配板和喷丝板进行参数化设计;以流变学基本原理为理论依据,研究高聚物熔体在纺丝组件内的流动机理,建立了熔体在皮芯型喷丝孔中流动的速度数学模型,并用Gambit对皮芯型喷丝孔建立三维模型和网格划分,利用专用CFD软件—Fluent对熔体在其中的流动情况进行了模拟;对大容量皮芯型纺丝组件设计了两套分配板方案,分别对其进行建模、网格划分和熔体流动模拟,通过计算出口的速度不匀率控制在1.5%得出了合理的分配板结构,速度不匀率反映了所纺纤维的条干不匀率,这将为实际实验和生产提供一定的理论依据。
最后,通过模拟所得参数和某公司的设计基础参数设计出一套大容量皮芯型复合纺丝组件,并结合该公司实际生产情况对低熔点棉生产工艺进行研究,取得了良好的效果。
目前国内对纺丝组件的设计大多限于经验,大容量的纺丝组件设计国内还没有报道,本论文最大的意义在于打破了常规组件的设计思路,首次得到皮芯型双组分熔体流动特性的计算模型,并结合如今强大的计算机CAD/CAE功能,基本上实现了在计算机上设计并模拟纺丝,不但节约了实际生产成本又提高了效率,使纺丝组件的设计步入了一个新的阶段。
Entering the 21st century, with the constant progress of the worldwide chemical fiber industry on manufacturing capacity, technical equipment, variety development and product quality, the new synthetic fibers are moving to the direction of large-capacity and ultra-fine. China's chemical fiber production has been the forefront of the highest in the world, but because of the bottleneck restriction on scale, differentiation rate and so on, the product's international competitiveness is not strong, and at present, the large-capacity spinning equipments still rely on imports. The function of spinning component immediately affects the fiber's spinnability and various performance norm. So the design and development of large-capacity spinning component is particularly important. So the design and development of large-capacity spinning component is particularly important.
This dissertation analyzed the structure of large-capacity spinning component, parametric designed for distribution and spinneret of the spinning component. According to basic theory of rheology and spinning technology, discussed rheological behavior of polymer melt when flowing in the large-capacity spinning component. Establishing velocity mathematical model of polymer melt flowing in the sheath-core orifices, then made 3D model and meshed them by Gambit, using the software of CFD-Fluent to simulate polymer melt flowing in the sheath-core orifices to find a reasonable dimension. Designed two sets of distribution system of large-capacity spinning components, made models, meshed and simulated the flowing respectively by Fluent to searching out reasonable distribution system of large-capacity spinning component. Unevenness of velocity was less than 1.5%, Unevenness of velocity expresses the fiber' s Unevenness. This provide theory basis for experiment and production.
Finally, we got the reasonable parameters by the simulation and designed a set of large-capacity sheath-core spinning component with the basic parameters of the company. This provided theoretical guidance for the company in production technology of low-melting point polyester. According to this, achieved some good results.
Spinning components have been designed mostly by experience so far in internal, there has been no report about the designing of large-capacity spinning component until now in internal. This dissertation broke up the routine design method which was the most import. Combing with the powerful CAD/CAE capability of computer we can design spinning component by computer which save not only production cost but also increasing efficiency. So that the design of spinning component will enter a new stage.
引文
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[4]江运礼,大容量涤短成套设备不再完全依赖进口,中国纺织报纺机,2007.4:002。
[5]柳和生,涂志刚,孙燕萍,聚合物口模挤出流动分析方法,高分子通报,2001.No.4:43-49。
[6]国产化纤产业用丝技术与纺丝设备的现状和开发,2006/2007,中国纺织工业技术进步研究报告。
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[9]魏大昌主编,化纤机械设计原理,纺织工业出版社,1984。
[10]吴大成等编,合成纤维熔体纺丝,纺织工业出版社,1980。
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[16]Ben Odom.National Jet-Using Wire EDM in Manu facturing Spinnerttes.International Fiber Journal,1997,12,(3):52-54.
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[18]秦伟明,大容量、多孔细旦熔纺喷丝板微孔间距的设计,合成纤维,1999.Vol.28 No.6:42-46。
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[24](美)SolidWorks公司著生信实维公司编译,SolidWorks API二次开发,机械工业出版社,2005。
[25]尹平平,陈冰冰,喷丝板微孔中熔体流动及异形纤维成形过程的研究,东华大学,2006。
[26]孙文策主编,工程流体力学,大连理工大学出版社,2002年08月第2版。
[27]ZiabickiA.Studies on theOrientation Phenomena by Fiber Forma2 tion from PolymerMelts Part Ⅱ Theoretical Considerations[J].JApp l Polym Sci,1959,2(4):24231.
[28]Ziabicki A,Kedzierska K.Studies on the Orientation Phenomena by Fiber Formation from PolymerMelts Ⅲ Effect of Structure on O2 rientation Condensation Polymers[J].J App l Polym Sci,1962,6(19):1112119.
[29]Ziabicki A,Kedzierska K.Studies on the Orientation Phenomena by Fiber Formation from Polymer Melts Ⅳ Effect of Molecular Structure on Orientation.Polyethylene and Polystyrene[J].J App 1 Polym Sci,1962,6(21):3612367.
[30]Kase S,Matsuo T.Studies on melt sp inning Ⅰ Fundamental Equa2tions on the Dynamics of Melt Sp inning Part A:General papers[J].J App 1 Polym Sci,1965,3(7):254122554.
[31]Kase S,Matsuo T.Studies on Melt Sp inning Ⅱ Steady2state and Transient Solutions of Fundamental Equations Compared with Ex2perimental Results[J].J App 1 Polym Sci,1967,11(2):2512287.
[32]Oh T H,LeeM S and Kim S Y.Numerical Simulation of theMelt Sp inning of Hollow Fibers[J].Journal Textile Research.1998,(6):4492456.
[33]Oh T H,Lee M S,Kim S Y,et al.Studies on Melt2Sp inning Process of Hollow Fibers[J].J App 1 Polym Sci,1998,68,120921217.
[34]王华平,余晓蔚,韩淑丽,熔纺中空纤维皮芯结构的动力学模拟[J],纺织学报,1999(4):71-74。
[35]王华平,余晓蔚,朱建民,熔纺中空纤维皮芯结构的形成原理及动力学模拟[J],合成纤维工业,1999(5):124。
[36]陈涛,张国亮主编,化工传递过程基础,化学工业出版社,2002。
[37]孙智,吴晓蓉,计算流体力学数值模拟方法的探讨及应用,水利科技与经济,2008.Vol.114 No.12:42-46。
[38]李学章,郭奕崇,马玉林,常用聚合物加工过程CAE软件的比较分析,塑料,2004.Vol.33 No.6:58-62。
[39]韩占忠,王敬,兰小平编,FLUENT流体工程仿真计算实例与应用,北京理工大学出版社,2004。
[40]刘金武,龚金科,倪小丹等,内燃机缸内流体动力学(CFD)仿真系统的开发与应用,湖南工程学院学报:自然科学版,2005,15(2)。
[41]于蕾,李敏,林豹等,FLUENT软件在射流模拟中的应用,科技情报开发与经济,2005,15(13)。
[42]许辉,邹早建,基于FLUENT软件的小水线面双体船粘性流数值 模拟,武汉理工大学学报:交通科学与工程版,2004,28(1)。
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[2]付刚,我国涤纶短纤维技术现状及行业发展中的若干问题,合成纤维,2005.Vol.34 No.1:1-4。
[3]魏家瑞,大容量直接纺涤纶短纤维装置技术新进展,合成技术及应用,1999.Vol.14 No.1:30-33。
[4]江运礼,大容量涤短成套设备不再完全依赖进口,中国纺织报纺机,2007.4:002。
[5]柳和生,涂志刚,孙燕萍,聚合物口模挤出流动分析方法,高分子通报,2001.No.4:43-49。
[6]国产化纤产业用丝技术与纺丝设备的现状和开发,2006/2007,中国纺织工业技术进步研究报告。
[7]张大省主编,超细纤维生产技术及应用,中国纺织出版社,2007。
[8]王妮,超细纤维的生产与应用,棉纺织技术,2001.Vol.29 No.7:27-30。
[9]魏大昌主编,化纤机械设计原理,纺织工业出版社,1984。
[10]吴大成等编,合成纤维熔体纺丝,纺织工业出版社,1980。
[11]侯庆华,戴玲,新型复合长丝的开发及应用,合成纤维,2006.No.5:44-50。
[12]Chang TK,John C.Influence of Polymer Characteristics and Melt-spinning Conditions on the Production of Fine Denier Poly(Ethylene Terephthalate) Fibers (Part 1):Rheological Characterization of PET Polymer Melt Fibers[J].JAPS,1992,46:55-65.
[13]Chang TK,John C.Influence of Polymer Characteristics and Melt-spinning Conditions on the Production of Fine Denier Poly(Ethylene Terephthalate) Fibers (Part 2):Melt spinning Dynamics[J].JAPS,1992,46:57-82.
[14]Chang TK,John C.Influence of Polymer Characteristics and Melt-spinning Conditions on the Production of Fine Denier Poly(Ethylene Terephthalate) Fibers (Part 3):Structure and Properties of Fine Denier As-spun PET Fibers[J].JAPS,1992,46:83-97.
[15]Jing-peir Yu著,张胜一译,胡韶华校,复合纤维喷丝板的设计,国外纺织技术,1998.No.11:12-15。
[16]Ben Odom.National Jet-Using Wire EDM in Manu facturing Spinnerttes.International Fiber Journal,1997,12,(3):52-54.
[17]Sang Young Kim.Dae Han Precision Co.Ltd.-Striving to Deliver 'Absolute Perfection'.International Fiber Journal,1997,12,(3):58.
[18]秦伟明,大容量、多孔细旦熔纺喷丝板微孔间距的设计,合成纤维,1999.Vol.28 No.6:42-46。
[19]王越,杨崇倡,王华平,徐雷麟,王学利,张敏,喷丝板的发展现状,纺织机械,2001.Vol.6:45-48。
[20]张峰,李兆前,黄传真,参数化设计地研究现状与发展趋势,机械工程师[J]2002(1):13-15。
[21]王卫荣,齐芬,SolidWorks的二次开发在箱体类零件中的应用,机械工程与自动化[J],2007(2):33-34。
[22]周凯旋,罗会信,基于VisualBasic的SolidWorks二次开发,机械制造[J],2005(5):46-48。
[23]王晓丽,季忠,SolidWorks的二次开发方法比较,现代制造技术与装备[J],2006(2):50-52。
[24](美)SolidWorks公司著生信实维公司编译,SolidWorks API二次开发,机械工业出版社,2005。
[25]尹平平,陈冰冰,喷丝板微孔中熔体流动及异形纤维成形过程的研究,东华大学,2006。
[26]孙文策主编,工程流体力学,大连理工大学出版社,2002年08月第2版。
[27]ZiabickiA.Studies on theOrientation Phenomena by Fiber Forma2 tion from PolymerMelts Part Ⅱ Theoretical Considerations[J].JApp l Polym Sci,1959,2(4):24231.
[28]Ziabicki A,Kedzierska K.Studies on the Orientation Phenomena by Fiber Formation from PolymerMelts Ⅲ Effect of Structure on O2 rientation Condensation Polymers[J].J App l Polym Sci,1962,6(19):1112119.
[29]Ziabicki A,Kedzierska K.Studies on the Orientation Phenomena by Fiber Formation from Polymer Melts Ⅳ Effect of Molecular Structure on Orientation.Polyethylene and Polystyrene[J].J App 1 Polym Sci,1962,6(21):3612367.
[30]Kase S,Matsuo T.Studies on melt sp inning Ⅰ Fundamental Equa2tions on the Dynamics of Melt Sp inning Part A:General papers[J].J App 1 Polym Sci,1965,3(7):254122554.
[31]Kase S,Matsuo T.Studies on Melt Sp inning Ⅱ Steady2state and Transient Solutions of Fundamental Equations Compared with Ex2perimental Results[J].J App 1 Polym Sci,1967,11(2):2512287.
[32]Oh T H,LeeM S and Kim S Y.Numerical Simulation of theMelt Sp inning of Hollow Fibers[J].Journal Textile Research.1998,(6):4492456.
[33]Oh T H,Lee M S,Kim S Y,et al.Studies on Melt2Sp inning Process of Hollow Fibers[J].J App 1 Polym Sci,1998,68,120921217.
[34]王华平,余晓蔚,韩淑丽,熔纺中空纤维皮芯结构的动力学模拟[J],纺织学报,1999(4):71-74。
[35]王华平,余晓蔚,朱建民,熔纺中空纤维皮芯结构的形成原理及动力学模拟[J],合成纤维工业,1999(5):124。
[36]陈涛,张国亮主编,化工传递过程基础,化学工业出版社,2002。
[37]孙智,吴晓蓉,计算流体力学数值模拟方法的探讨及应用,水利科技与经济,2008.Vol.114 No.12:42-46。
[38]李学章,郭奕崇,马玉林,常用聚合物加工过程CAE软件的比较分析,塑料,2004.Vol.33 No.6:58-62。
[39]韩占忠,王敬,兰小平编,FLUENT流体工程仿真计算实例与应用,北京理工大学出版社,2004。
[40]刘金武,龚金科,倪小丹等,内燃机缸内流体动力学(CFD)仿真系统的开发与应用,湖南工程学院学报:自然科学版,2005,15(2)。
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