| Course Code： | MEE476*T |
| Course Name(in Chinese)： | 高分子材料加工机械设计 |
| Course Name(in English)： | Design of Polymer Processing Machines |
| Course Category： | Subject Direction and Distinctive Compulsory Course |
| Target Studendts： | Mechanical Engineering and Automation |
| Term Avaiable： | Autumn |
| Total Credit Hours： | 64 |
| Total Credits： | 4 |
| Prerequisites（Course Code）： | Polymer physical chemistry and formula（）Polymer processing theory（） |
| Parallels（Course Code）： | Mold Design（）Head Design（）Mixture Theory and equipment（）Special Extruder Design（） |
| Course Descriptions： | Briefly introduced important properties of the polymer material, molding processing and the thermoplastic plastic. The teaching focus on the related theory, the working principle, structural features and design points of the single screw extruder and the injection machine. Briefly introduced the working principle, structural features and design points of the roll mixer, the lanbury mixer and the calendar. |
| Textbooks Recommended： | Lianxun Fen, Yuguang Yang. Self Atlas. Beijing University of Chemical Technology, 2003 |
| Supplementary Materials: | [1] Friedhelm Hensen．Plastic Extrusion Technology. Beijing: Light Industry Press.2001. [2] Fuhua Zhu．Extrusion Theory and Application．Beijing：Light Industry Press，2001 [3] Fuhua Zhu．Screw design and its theoretical basis．Beijing：Light Industry Press，1984 [4] Beijing University of Chemical Technology，South China University of Technology．Plastic Mechanical Design．Beijing：Light Industry Press，1995 [5] Guojun Tang，Jianbin Li．Rubber Machinery Design．Beijing: Chemical Industry Press, 1997 [7] Xingtian Wang. Plastic molding technology. Beijing: Chemical Industry Press, 1993 [8] Jinping Qu and so on. Plastic Industry Manual - injection molding, molding techniques and equipment. Beijing: Chemical Industry Press, 2001 |
Learning Goals and Objectives
Through lectures, homework, laboratory and manufacturing practice and other links
1. to develop students’ rigorous and realistic scientific attitude and meticulous work style.
2. to make students to understand the development status of national polymer processing machine and the gap with industrialized countries.
3. enable students to master the basic theoretical knowledge and design methods of the typical equipment.
4. focus on self-learning abilities, so that students can obtain knowledge from the relevant reference books and literature.
5. enable students to master the basic principles of the processing for a typical machine, the relationship between factors and the impact on the final product quality, improving their ability to think.
6. enable students have logical reasoning ability to infer other things from one fact based on who have mastered the principles, the structure and the design method of a typical machine.
Course Content and Requirments
Introduction (4 Credit Hours)
Polymer materials and molding process; The status quo of the polymer materials and processing industry in China.
Plastic molecular structure; Thermoplastics’ physical changes, rheology, physical properties.
Basic requirements:
1. Understanding the classification of plastics, rubber and their the main molding processing methods.
2. Mastering the classification of thermoplastics and the important properties which closely related to forming processing and mechanical design.
Part One: Extruder (22 Credit Hours)
Chapter One: Introduction (2 Credit Hours)
The brief introduction of the plastic extrusion’s development; Extrusion characteristics and equipment composition; The classification of the plastic extruder.
Basic requirements:
1. Understand the characteristics of extrusion and their equipment composition.;
2. Understand the classification of the plastic extrusion machine.
Chapter Two: The Single-Screw Plastic Extruder (1 Credit Hour)
The mark of the single-screw plastic extruder; The main technical parameters; Structure; Geometric parameters of the screw; Extrusion process.
Basic requirements:
1. Understand the meaning of main technical parameters;
2. Understand the structure, the composition and the function of the single-screw extruder;
3. Master o screws’ Geometric parameters and extrusion process.
Chapter Three: The Extrusion Theory (8 Credit Hour)
Solid conveying theory: The model and equations of the solid conveying theory; The discussion of the Solid conveying rate Equation; The consumption of the solid conveying rate.
Melting theory: Melting model; The mathematical function of the melting theory; The influence of physical properties and process conditions on the melting process.
Melting conveying theory: Theoretical model of the melt conveying; Formula for measuring productivity in metering section; The discussion of the productivity formula; The consumption of the melt conveying rate.
Basic requirements:
1. According to the relevant plan, understand the basic ideas and ****ysis methods of each theoretical model;
2. Understand the deduction process of the three major theoretical formula;
3. Master the impact of the tran**ission angle and the friction coefficient on solid conveying rate, and measures to enhance the solid conveying rate;
4. Master the law, physical properties and process conditions which are described by the mathematical function of the melting theory;
5. Master the composition of the productivity formula in metering section;
6. Master the concept of the screw characteristics, die properties, extruder working points and the effective working area;
7. Understand the impact of screw parameters, process conditions, physical properties on the production rate;
8. Understand the power consumption of solid conveying, melting and melt conveying.
Chapter Four: The Design of The Extrusion System (11 Credit Hour)
Measuring standard for the screw property: production, energy consumption, extrusion material quality, economy.
Ordinary screw design: structure, the main parameter’s determine, the existent problem.
New screw design:
Barrel design: the structure; the existent problem of the ordinary barrel; Axial slotted bushing; the existent problem of the IKV system; the feed port design; the connection structure between barrel and cross-head.
Understand the material selection, surface treatment, strength calculation and combination requirement for screw and barrel.
Basic requirements:
1. Understand and familiar with the measuring standard for the screw property;
2. Master the structure and the use of the ordinary screw, and its method of determining the main parameters;
3. Master existent problems of the ordinary screw, and know why it can not be solved by itself;
4. Master the working principle of the four types of new screw, and its basic structural features and design elements;
5. Understand the structure the barrel and the existent problem of the ordinary barrel;
6. Understand and be familiar with the working principle, structure and design elements of axial slotted feed bushing.
7. Understand the existent problem of the IKV system;
8. Understand the design of the feeding port, barrel and head connect structure;
9. Understand requirements of the material selection, surface treatment, strength calculation and combination requirement for screw and barrel.
Chapter Five: The Design of The Feeding System (carried out in production practice)
Feeding system components and requirements; feeding methods; automatic feeding device.
Basic requirements:
1. Understand the requirements and the composition of extruder feeding systems;
2. Understand feeding methods of the extruder;
3. Understand the composition of different feeding devices, and their working principle.
Chapter Six: Tran**ission System Design (carried out in production practice)
Extruder operating characteristics with constant torque;
Requirements to transfer speed when determine the device power;
The composition, speed control method and characters of the Tran**ission system;
Tran**ission system arrangement, the thrust bearing arrangement, closed forces system, overload protection.
Basic requirements:
1. Understand constant power operating characteristics of the extruder;
2. Understand the method to determine the drive power and requirements to the speed of the screw;
3. Understand the characteristics of each speed control method;
4. Understand the closed forces system how to form in gearbox which is not impacted by axial force.
Chapter Seven: Heating and Cooling System Design (carried out in production practice)
Analysis of heat balance and assignment of heating and cooling section;
The method to determine the heating power, heat method and characteristics;
The cooling of the Barrel, 加料斗座 and screw;
Extruder temperature control system components and features.
Basic requirements:
1.Understand the thermal balance ****ysis and temperature control segmentation;
2.Understand the method to determine the heating power, heating method and characteristics;
3.Understand the cooling method and characteristics of the extruder;
4.Understand the composition and characteristics of the temperature control system.
5.
Chapter Eight: Rubber Extruder (carried out in production practice)
Rubber extruder structure, working principle and technical parameters;
Differences of the barrel and the screw structure between rubber extruder and plastic extruder;
Rubber extruder heating and cooling method and structure;
The feeding method and the structure of the rubber extruder.
Basic requirements:
1.Understand the structure, the working principle and technical parameters of the rubber extruder;
2.Understand the differences of the barrel and the screw structure between rubber extruder and plastic extruder;
3.Understand the heating and cooling method and the structure of the rubber extruder;
4.Understand the feeding method and the structure of the rubber extruder.
Part Two: Injection Molding Machine(25 credit hours)
Chapter One: Introduction (2 Credit Hours)
Plastic injection molding process; Injection machine component; Injection molding principle
Basic requirements:
1. Master the concept of injection molding and the molding cycle composition;
2. Familiar with the characteristics of injection molding;
3. Understand the composition of the molding machine and the classification method which according to the ordered principle of the machine structure.
Chapter Two: The Basic Parameters of Injection Machine (4 Credit Hours)
The parameters of Injection section; The parameters of clamping unit; Comprehensive technical and economic indicators.
Basic requirements:
1. Master the definition of each parameter;
2. Master the conversion relationship between various parameters;
3. Familiar with the principles of determining and selecting parameters when design the injection machine.
4. Understand the impact of various parameters on the injection machine structure.
Chapter Three: Injection Molding Device (6 Credit Hours)
The Classification and the composition of the injection molding equipment; Screw-type injection device working principle and structure;
Screw-type injection device design points;
Injection device development.
Basic requirements:
1. Master the classification method, the composition, and structural characteristics of injection molding device;
2. Master screw-type injection device working principle and structure;
3. Familiar with design method and points of the screw-type injection device;
4. Understand the development trend of injecting equipment.
Chapter Four: Clamping Device (8 Credit Hours)
The Classification and the composition of the clamping unit;
Hydraulic clamping device working principle, parameters and structure;
Toggle clamping device working principle, parameters and structure;
Hydraulic clamping device design points;
Toggle clamping device design points.
Basic requirements:
1.Master mold device classification, composition and structural characteristics;
2.Master the working principle, parameters and the structure of the hydraulic clamping device;
3.Master the working principle, parameters and the structure of the toggle clamping device;
4.Master hydraulic clamping device design points;
5.Master toggle clamping device design points;
6.Familiar with the advantages and disadvantages of two clamping devices and selection principles;
7.Understand the system deformation process, the design process and the calculation of strength and stiffness for toggle-clamping device.
Chapter Five: The Drive of Injection Machine (2 Credit Hours)
Injection machine drive requirements; Injection machine drive power; The thermal power of injection machine for heating.
Basic requirements:
1. Master the drive requirements to injection machine;
2. Master the drive style and characteristics of injection machine;
3. Master the method to determine the drive power;
4. Understand the method to determine the thermal power of injection machine.
Chapter Six: The Control of the Injection Machine (2 Credit Hours)
The procedures and requirements of the Injection machine;
The movement program control of the injection machine;
The process program control of the injection machine;
The application of the computer in injection machine control
Basic requirements:
1.Understand the procedures and requirements of the injection machine;
2.Understand the movement program control and the process program control of the injection machine;
3.Understand the application of the computer in the injection machine control.
Chapter Seven: The Development of the Injection Machine (1 Credit Hour)
Introduce the latest technical development of the injection machine.
Part Three: Plastic mixing equipment (5 Credit Hours)
Chapter One: The Roll Mixer (1.5 Credit Hours)
The application and classification of the roll mixer;
The basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the roll mixer
Basic requirements:
1.Understand the application and the classification of the roll mixer;
2.Understand the basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the roll mixer.
Chapter Two: The Banbury Mixer (1.5 Credit Hours)
The application and classification of the Banbury Mixer;
The basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the Banbury mixer;
The rotor structure of the intermittent and continuous mixer
Basic requirements:
1.Understand the application and classification of the Banbury Mixer;
2.Understand the basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the banbury mixer;
3.Understand the working principle of the intermittent and continuous mixer and the difference between the rotor structure.
Chapter Three: The calendar (2 Credit Hours)
The application and classification of the calendar;
The basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the calendar;
The compensation measures of the calendar roll deflection.
Basic requirements:
1. Understand the application and the classification of the calendar;
2. Understand the basic structure, the working principle, the main technical parameters, tran**ission form and the main components of the calendar;
3. Master the compensation measures of the calendar roll deflection.
Assignment
1. Extrusion experiment (2 Credit Hours)
Measure the extruder output, torque, power, pressure, speed and other parameters, organize the experimental data, draw the corresponding curve and ****yse the relationship between parameters. Finally, complete experimental report.
2. Plate vulcanizing machine experiment (2 Credit Hours)
Measure the stress of the pate vulcanizing machine column, ****yse of the stress state and the reason for uneven load of each column, then calculate the clamping force, correct choice the pressure area of the mold according to the clamping force .Finally, complete experimental report.
3. Injection Machine Experiment (4 Credit Hours)
Familiar with the injection machine operation and requirements, measure its injection volumes, plasticizing capacity and back pressure, screw speed, the relationship between the deformation and the clamping force of the toggle clamping unit.
Assignment
Assignmentlayout teaching exercises and thoughts of each chapter.
Promote and encourage students to discuss the assignment, but eventually completed the assignment independently
Evaluation Approaches
The final exam is close-book, within 120minutes.
The evaluation for experiments is based on the performance of the experiments report and results.
Asses**ent System
Grading is by percentages, with 100 as the maximum grade; it distributes as follow:
Final grades: 80%
Assignments: 20%