Structure analysis for refrigerator molding layer door based on polymer foaming simulation

doi:10.11949/0438-1157.20200056

Abstract

Abstract:

Since the thermal insulation structure with foam layer is one issue in current refrigerator production, the physical parameters in polymer foaming process are studied, and the simulation method of foam layer based on changing these physical parameters is proposed to optimize the structural design of refrigerator doors. Informed by theoretical analysis of polymer foaming process, these physical parameters related to foaming layer structure is discussed, and their changing and expression is analyzed. Based on the statistical data from literature and the polymer foaming experiments, the simulation model of foaming process with CFD-UDF is established, to analyze the refrigerator door structure. At last, one refrigerator door is proposed as the instance to discuss its physical parameters and foam layer structure, and to validate this CFD-UDF model.

Key words: foaming process, physical parameter simulation, CFD simulation, door structure

摘要：

针对制冷类产品中隔热发泡层结构的设计问题，分析聚合物发泡过程的物理特性，提出了基于发泡过程参数演化的发泡层结构仿真模型，用于指导相关冰箱门体结构优化设计。结合聚合物发泡工艺的理论过程分析，提取并分析发泡层结构相关联的物理参数演化规律，提出其相应函数表达。通过文献调研及发泡工艺实际模拟实验，分别获取其相关物理参数的统计数据及实际表达，并基于CFD-UDF构建了发泡过程仿真模型，用于冰箱门体结构模拟分析。最后，结合某款冰箱门体结构，分析其发泡层成型状态及过程参数，验证了该发泡过程CFD-UDF仿真模型的有效性。

关键词: 发泡过程, 物理参数模拟, CFD仿真, 门体结构

CLC Number:

TQ 328

Qingdi KE, Jie YANG, Qiankun LI, Yaming TIAN. Structure analysis for refrigerator molding layer door based on polymer foaming simulation[J]. CIESC Journal, 2020, 71(S2): 273-280.

柯庆镝, 杨杰, 李乾坤, 田亚明. 基于聚合物发泡过程参数模拟的冰箱门体成型层分析[J]. 化工学报, 2020, 71(S2): 273-280.

Figures/Tables 14

References 30

1	张聪聪, 郑梦凯, 李伯耿. 软段结构对聚氨酯弹性体性能的影响[J]. 化工学报, 2019, 70(10): 4043-4051.
	Zhang C C, Zheng M K, Li B G. Effect of soft segment structure on properties of polyurethane elastomers [J]. CIESC Journal, 2019, 70(10): 4043-4051.
2	陈旭亮, 任强, 宋艳, 等. 基于醇胺固定-释放二氧化碳原理的聚氨酯泡沫绿色制备[J]. 化工学报, 2017, 68(11): 4383-4389.
	Chen X L, Ren Q, Song Y, et al. Ammonium carbamate from diethanolamine for green foaming of polyurethanes with carbon dioxide [J]. CIESC Journal, 2017, 68(11): 4383-4389.
3	干年妃, 王多华, 冯亚楠, 等. 聚氨酯泡沫填充的碳纤维增强复合材料锥管吸能性能数值模拟及试验验证[J]. 中国机械工程, 2018, 29(5): 609-615.
	Gan N F, Wang D H, Feng Y N, et al. Numerical simulation and experimental verification of energy absorption performance of PU foam filled CFRP cone tubes [J]. China Mechanical Engineering, 2018, 29(5): 609-615.
4	曲杰, 胡焱松, 岳凯, 等. 硬质聚氨酯泡沫在多轴压缩试验下的力学特性研究[J]. 机械工程学报, 2017, 53(20): 89-97.
	Qu J, Hu Y S, Yue K, et al. Research on the mechanical properties of rigid polyurethane foam in the multiaxial compression experiment [J]. Journal of Mechanical Engineering, 2017, 53(20): 89-97.
5	梁志鸿, 李建, 阚前华, 等. 形状记忆聚氨酯热力耦合变形行为实验和有限元模拟[J]. 材料工程, 2019, 47(10): 133-140.
	Liang Z H, Li J, Kan Q H, et al. Experiment and finite element simulation on thermo-mechanically coupled deformation behavior of shape memory polyurethane [J]. Journal of Materials Engineering, 2019, 47(10): 133-140.
6	Aboulkas A, El Harfi K, El Bouadili A, et al. Thermal degradation behaviors of polyethylene and polypropylene (I): Pyrolysis kinetics and mechanisms [J]. Energy Conversion and Management, 2009, 51(7): 1363-1369.
7	Özdemir B, Akar F. 3D simulation of polyurethane foam injection and reacting mold flow in a complex geometry [J]. Heat and Mass Transfer, 2018, 54: 1281-1288.
8	Abdessalam H, Abbès B, Abbès F, et al. Prediction of acoustic properties of polyurethane foams from the macroscopic numerical simulation of foaming process [J]. Applied Acoustics, 2017, 120: 129-136.
9	Karimi M, Marchisio D, Laurini E, et al. Bridging the gap across scales: coupling CFD and MD/GCMC in polyurethane foam simulation [J]. Chemical Engineering Science, 2018, 178: 39-47.
10	Marvi-Mashhadi M, Lopes C S, Llorca J. Effect of anisotropy on the mechanical properties of polyurethane foams: an experimental and numerical study [J]. Mechanics of Materials, 2018, 124: 143 -154.
11	于洋. 冰箱充型用硬质聚氨酯泡沫发泡过程数值模拟[D]. 合肥: 中国科学技术大学, 2011.
	Yu Y. Numerical simulation on refrigerator mold filling processes with rigid polyurethane foams [D]. Hefei: University of Science and Technology of China, 2011.
12	李乾坤, 柯庆镝, 田亚明, 等. 基于CFD的冰箱门体发泡过程模拟方法[J]. 家电科技, 2019, (3): 82-84+89.
	Li Q K, Ke Q D, Tian Y M, et al. Simulation method of fridge door foaming process based on CFD [J]. Journal of Appliance Science & Technology, 2019, (3): 82-84+89.
13	Geier S, Winkler C, Piesche M. Numerical simulation of mold filling processes with polyurethane foams [J]. Chemical Engineering & Technology, 2009, 32(9): 1438-1447.
14	王铁军, 张文君, 杨海明, 等. 便携式斯特林深冷冰箱研制[J]. 制冷学报, 2011, 32(2): 27-29+49.
	Wang T J, Zhang W J, Yang H M, et al. Development of portable Stirling cryogenic refrigerator [J]. Journal of Refrigeration, 2011, 32(2): 27-29+49.
15	Bikard J, Bruchon J, Coupez T, et al. Numerical prediction of the foam structure of polymeric materials by direct 3D simulation of their expansion by chemical reaction based on a multidomain method [J]. Journal of Materials Science, 2005, 40(22): 5875-5881.
16	Yang W J, Lee G Y, Park S H. Analysis on chemical and physical behaviors of polyurethane foam for prediction of deformation of refrigerator panels [J]. International Journal of Precision Engineering and Manufacturing, 2019, 20(12): 2041-2049.
17	Seo D, Youn J R. Numerical analysis on reaction injection molding of polyurethane foam by using a finite volume method [J]. Fluid Phase Equilibria, 2005, 46(17): 6482-6493.
18	Charles A, Harper. Handbook of Plastics and Elastomers [M]. New York: McGraw-Hill, 1975: 223.
19	Castro J M, Macosko C W. Kinetics and rheology of typical polyurethane reaction injection molding systems [C]// Soc. Plast. Eng. Tech. Pap. Annu. Tech. Conf. 1980: 434-438.
20	Rojas A J, Marciano J H, Williams R J. Rigid polyurethane foams: a model of the foaming process [J]. Polymer Engineering and Science, 1982, 22(13): 840-844.
21	Nian X B, Liu H, Li Y W, et al. Numerical simulation of the fluid traverses the porous media by single domain method based on UDF [J]. Procedia Engineering, 2017, 205: 3946-3953.
22	Anirudh A M, Thibaut M, Jorge C B, et al. A 3D moment of fluid method for simulating complex turbulent multiphase flows [J]. Computers and Fluids, 2020, 198: 104364-104371.
23	Yin X G, Zarikos I, Karadimitriou N K, et al. Direct simulations of two-phase flow experiments of different geometry complexities using volume-of-fluid (VOF) method [J]. Chemical Engineering Science, 2019, 195: 820-8270.
24	Abbassi W, Besbes S, Elhajem M, et al. Numerical simulation of free ascension and coaxial coalescence of air bubbles using the volume of fluid method (VOF) [J]. Computers and Fluids, 2018, 161: 47-59.
25	Aniszewski W, Ménard T, Marek M. Volume of fluid (VOF) type advection methods in two-phase flow: a comparative study [J]. Computers and Fluids, 2014, 97: 52-73.
26	Du W, Zhang J Z, Lu P P, et al. Advanced understanding of local wetting behavior in gas-liquid-solid packed beds using CFD with a volume of fluid (VOF) method [J]. Chemical Engineering Science, 2017, 170: 378-392.
27	吴海英. 冰箱门体模块的参数化设计[D]. 济南: 山东大学, 2019.
	Wu H Y. Parametric design of refrigerator door modular [D]. Jinan: Shandong University, 2019.
28	郭刚, 游飞越, 孔冬, 等. 基于数值分析的冰箱门体结构优化[J]. 电器, 2011, (S1): 58-62.
	Guo G, You F Y, Kong D, et al. Structural optimization of refrigerator door based on numerical analysis [J]. China Appliance, 2011, (S1): 58-62.
29	王怀民, 黄承成, 朱涛. 对开门冰箱门体结构优化设计[J]. 家电科技, 2015, (6): 55-57.
	Wang H M, Huang C C, Zhu T. The optimization design of the refrigeration door based on the side-by-side refrigerator [J]. Journal of Appliance Science & Technology, 2015, (6): 55-57.
30	Gyu H L, Byung K P, Woo I L. Microstructure and property characterization of flexible syntactic foam for insulation material via mold casting [J]. International Journal of Precision Engineering and Manufacturing - Green Technology, 2017, 4(2): 169-176.

组分	质量分数/%
多元醇（HO-R′-OH）	30~45
催化剂	3~4
物理发泡剂	15
水（H₂O）	1~2
异氰酸酯（OCN-R-NCO）	40~60
其他必要成分	2~4

组分	质量分数/%
多元醇（HO-R′-OH）	30~45
催化剂	3~4
物理发泡剂	15
水（H₂O）	1~2
异氰酸酯（OCN-R-NCO）	40~60
其他必要成分	2~4

反应时间/s	H_min/cm	H_max/cm	H_t/cm	V_实验/cm3	V_仿真/cm3	误差/%	密度/ (kg/m³)
4.0	1.70	1.70	1.70	534.056	555.61	4.04	926.87
8.0	3.50	3.50	3.50	1099.53	1015.93	7.61	450.19
12.0	5.40	5.40	5.40	1696.41	1728.14	1.87	291.79
16.0	7.60	7.80	7.70	2418.96	2620.24	8.32	204.63
20.0	11.10	11.40	11.25	3534.19	3602.71	1.95	140.06
24.0	15.70	16.60	16.15	5073.52	4782.62	5.75	97.57
28.0	20.90	21.70	21.30	6691.40	6451.81	3.60	73.98
32.0	26.50	27.40	26.95	8466.34	8878.54	4.88	58.47
36.0	33.20	35.50	34.35	10791.05	11757.58	8.94	45.87
40.0	37.40	39.70	38.55	12110.48	13301.12	9.84	40.87
44.0	40.10	43.70	41.90	13162.89	14108.11	7.29	37.61

反应时间/s	H_min/cm	H_max/cm	H_t/cm	V_实验/cm3	V_仿真/cm3	误差/%	密度/ (kg/m³)
4.0	1.70	1.70	1.70	534.056	555.61	4.04	926.87
8.0	3.50	3.50	3.50	1099.53	1015.93	7.61	450.19
12.0	5.40	5.40	5.40	1696.41	1728.14	1.87	291.79
16.0	7.60	7.80	7.70	2418.96	2620.24	8.32	204.63
20.0	11.10	11.40	11.25	3534.19	3602.71	1.95	140.06
24.0	15.70	16.60	16.15	5073.52	4782.62	5.75	97.57
28.0	20.90	21.70	21.30	6691.40	6451.81	3.60	73.98
32.0	26.50	27.40	26.95	8466.34	8878.54	4.88	58.47
36.0	33.20	35.50	34.35	10791.05	11757.58	8.94	45.87
40.0	37.40	39.70	38.55	12110.48	13301.12	9.84	40.87
44.0	40.10	43.70	41.90	13162.89	14108.11	7.29	37.61

设置内容	参数
模型尺寸（圆柱体）	直径D=0.2 m,高H=1 m
流体域	整个圆柱体
网格划分软件	Fluent Meshing
网格尺度	10~15 mm
网格类型	多面体-六面体核心
网格质量	0.3972
总网格数	31769个
模拟方法	瞬态
出口边界设置	圆柱体上表面
多相流模型	VOF模型
初相	空气
次相	PU泡沫
初相设定	Fluent材料库
次相设定	自定义函数（UDF）设定
湍流模型	标准k-ε方程模型
壁面函数	标准壁面函数
出口边界条件	压力出口边界条件
速度和压力耦合求解算法	PISO算法
初始条件	大气条件