桨形螺杆元件开发及其柔性混合能力分析

doi:10.11949/0438-1157.20250850

摘要/Abstract

摘要：

针对含能材料开发了一种桨形螺杆元件，通过有限元数值仿真方法对不同螺杆元件的剪切分散能力及输送分布效果进行了比较，并结合晶体物料破碎行为研究了不同螺杆元件对固体颗粒的破碎效果，以此分析适用于特殊场景的双螺杆连续混合工艺的柔性混合能力。结果表明：开发的桨形元件对物料的剪切作用较弱，并且能够实现高通量的物料体积交换，其具备与其他螺杆元件相当的分布混合能力；在相同工艺条件下，输送-啮合块元件组合型螺杆制备的样品晶体颗粒粒径为单峰分布，输送-桨形元件组合型螺杆制备的样品晶体颗粒粒径为双峰分布，表明桨形螺杆元件对物料的混合作用较为柔和，物料验证性实验则证明了桨形螺杆元件能够实现混合均匀性，在针对具有刺激敏感性的含能材料加工领域具有应用潜力。

关键词: 桨形元件, 双螺杆挤出机, 柔性混合, 数值模拟, 含能材料

Abstract:

This study developed a paddle-shaped screw element for energetic materials and compared the shear dispersion capabilities and conveying distribution effects of different screw elements using finite element numerical simulation methods. The fragmentation behavior of crystal particles was also investigated to analyze the particle breakage effects induced by different screw elements, thereby evaluating the flexible mixing capability of twin-screw continuous mixing processes for specialized applications. The results indicated that the developed paddle-shaped element exerted weaker shear forces on the materials while achieving high-throughput volumetric exchange, demonstrating considerable distribution mixing performance comparable to other screw elements. Under identical processing conditions, samples prepared using a combination of conveying-meshing block elements exhibited a unimodal distribution of crystal particle sizes, whereas those produced with conveying-paddle-shaped element combinations showed a bimodal distribution. This suggests that the mixing effect of the paddle-shaped screw element was relatively gentle. Validation experiments further confirmed the ability of paddle-shaped screw elements to achieve uniform mixing and the potential application in processing stimulus-sensitive energetic materials.

Key words: paddle elements, twin-screw extruder, flexible blending, numerical simulation, energetic materials

中图分类号:

TQ 051.7

王彦杰, 褚岳健, 杨文明, 朱惠豪, 王玉, 李果, 谢林生. 桨形螺杆元件开发及其柔性混合能力分析[J]. 化工学报, DOI: 10.11949/0438-1157.20250850.

Yanjie WANG, Yuejian CHU, Wenming YANG, Huihao ZHU, Yu WANG, Guo LI, Linsheng XIE. Development of paddle screw elements and analysis of their flexible mixing capability[J]. CIESC Journal, DOI: 10.11949/0438-1157.20250850.

图/表 15

图1 桨形螺杆元件及柱形桨叶组结构的三维模型示意图注:(a) (b) (c)

Fig. 1 Schematic of 3D Model of Single Paddle Screw Element and Columnar Paddle Set Structure

图2 五种不同的螺杆元件: （a）桨形元件、（b）齿形元件、（c）大导程元件、（d）螺纹元件、（e）啮合块元件注:(a) (b) (c) (d) (e)

Fig. 2 Five Different Screw Elements: (a) gear profile element, (b) paddle profile element, (c) S element, (d) screw element, (e) meshing block element

图3 特征线的选择位置

Fig. 3 Selected position of the characteristic line

表1 模拟边界条件及工艺参数

Table 1 Boundary Conditions for Simulation and Parameters

边界位置	边界代号	边界条件
流体入口	inlet	体积流率8×10^-7m³/s
螺杆机筒内壁	outwall	壁面无滑移v_n=v_s=0
螺杆转速	/	60 rpm
流体黏度	η	10⁵ Pa·s
流体密度	ρ	1.6 g/cm³
流体出口	outlet	自由出口

图4 不同螺杆类型结构示意图

Fig. 4 Structure Diagram of Different Screw Types

图5 无水Na2SO4颗粒和NaCl颗粒的显微镜照片及初始粒径分布图

Fig. 5 Microscope Pictures and Initial Particle Size Distribution of Anhydrous Na2SO4 and NaCl Particles

图6 不同螺杆元件的最大剪切应力分布图

Fig. 6 The Distribution Plot of Maximum Shear Stress of Different Screw Elements

图7 不同螺杆元件的累计解聚功分布图

Fig. 7 The Distribution Plot of Mmix of Different Screw Elements

图8 不同螺杆元件的（a）轴向速度分布和（b）累计停留时间分布

Fig. 8 The Distribution Plot of Axial Velocity (a) and Cumulative Residence Time (b) of Different Screw Elements

图9 不同螺杆元件的修正Lyapunov指数分布

Fig. 9 The Distribution Plot of Modified Lyapunov Exponent of Different Screw Elements

图10 不同螺杆种类制备的样品实物图片和粒径分布图

Fig. 10 Pictures of Samples Prepared with Different Screw Types and Corresponding Size Distribution of Crystal Particles

表2 不同螺杆种类制备的样品中的晶体颗粒粒径分布

Table 2 Average Size of Crystal Particle in Samples Prepared with Different Screw Types

螺杆类型	啮合块-螺纹元件组合螺杆	桨形-螺纹元件组合螺杆
平均粒径	284.5 µm	302.2 µm

图11 不同取样区域的双螺杆结构及取样粒径分布的情况

Fig. 11 Twin-screw Diagrams of Specific Sampling Areas and Corresponding Size Distribution of Crystal Particles

表3 固化样品的密度测试值

Table 3 Density Value of Cured Samples

样品	质量/g	体积/cm³	密度/g/cm³	平均密度/g/cm³	标准差/ g/cm³	变异系数/ %
1	23.22	13.9	1.66	1.663	0.035	2.1
	23.75	14.0	1.70
	12.84	7.9	1.63
2	19.89	12.0	1.66	1.667	0.040	2.4
	14.19	8.3	1.71
	8.16	5.0	1.63
3	14.23	8.6	1.65	1.677	0.023	1.4
	8.47	5.0	1.69
	17.55	10.4	1.69

图12 混合样品图片

Fig. 12 Mixed Sample Pictures

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