Jiang Jinhui, Feng Yanhong, Gao Shuo, Yan Wenqiang, Yin Xiaochun, Zhang Guizhen
The National Engineering Research Center of Novel Equipment for Polymer Processing, South China University of Technology, Guangzhou 510641, China.
Key Laboratory of Polymer Processing Engineering, Ministry of Education, South China University of Technology, Guangzhou 510641, China.
Materials (Basel). 2025 Apr 24;18(9):1939. doi: 10.3390/ma18091939.
The eccentric rotor extruder (ERE) is polymer processing equipment that exhibits excellent processing capabilities for materials with extremely high viscosity, which are difficult to plastically deform and transport efficiently. However, the mass transfer mechanism in the solid conveying section of this new device is fundamentally different from that of traditional extruders, and no related research has been reported. This study uses discrete element method (DEM) simulation technology to model the solid conveying process of the ERE. By visualizing the positive displacement conveying process, and with an analysis of the output parameters, the study clarifies the mass transfer principles and quantifies the conveying capacity, providing guidance for optimizing the extruder design. The simulation results show that the ERE exhibits positive displacement conveying characteristics, with the conveying process achieved by the forward movement of the cavities (closed cavities between the rotor and stator) in a helical manner. However, differences in the dual-cavity (two types of cavities) feeding process and low fill level can lead to significant fluctuations in extrusion output and reduced conveying capacity. To address these issues, an improvement scheme for the dual-cavity feed opening is proposed, with feed openings designed with different opening lengths. Then, by analyzing the particle coordinate data from the simulation output, the conveying capacities of different feed opening structures are quantified and optimized. Finally, experimental and simulation verification results indicate that the optimized structure significantly improves the issues of uneven filling and low fill level, with good correspondence between the simulation and experimental results. Simulation results show that, compared with the original structure, the optimized dual-feed opening structure increases the feed capacity from 3953 particles per cavity to 5132 particles per cavity, an improvement of 29.8%, and it achieves balanced filling between the two cavities. Experimental validation indicates that the UPE4040 output can be increased from 165.3 g/min with structure op-00 to 231.7 g/min with the optimized structure op-05.
偏心转子挤出机（ERE）是一种聚合物加工设备，对于具有极高粘度、难以塑性变形且难以有效输送的材料具有出色的加工能力。然而，这种新型设备的固体输送段中的传质机制与传统挤出机的传质机制存在根本差异，且尚无相关研究报道。本研究采用离散元法（DEM）模拟技术对ERE的固体输送过程进行建模。通过可视化正位移输送过程，并分析输出参数，该研究阐明了传质原理并量化了输送能力，为优化挤出机设计提供了指导。模拟结果表明，ERE呈现正位移输送特性，输送过程是通过腔体（转子和定子之间的封闭腔体）以螺旋方式向前移动来实现的。然而，双腔体（两种类型的腔体）进料过程的差异和低填充水平会导致挤出产量出现显著波动并降低输送能力。为解决这些问题，提出了一种双腔体进料口的改进方案，进料口设计有不同的开口长度。然后，通过分析模拟输出的颗粒坐标数据，对不同进料口结构的输送能力进行量化和优化。最后，实验和模拟验证结果表明，优化后的结构显著改善了填充不均匀和填充水平低的问题，模拟结果与实验结果具有良好的一致性。模拟结果表明，与原始结构相比，优化后的双进料口结构将进料能力从每腔体3953个颗粒提高到每腔体5132个颗粒，提高了29.8%，并且实现了两个腔体之间的平衡填充。实验验证表明，UPE4040的产量可以从结构op - 00时的165.3克/分钟提高到优化结构op - 05时的231.7克/分钟。
