聚酯制件精密注塑成型及其性能调控基础研究

Nowadays screw injection machines are widely used for polyester products at home and abroad. The high shear deformation during processing will lead to non-uniform temperature field and even produce local high temperature, which will cause negative impact on the molding precision of products, especially for multi-cavity molding, and service properties of products. The precision multi-cavity injection molding and performance-based regulation of polyester products will be realized by making the materials flow through spaces of which the volume changed periodically during the plasticizing and conveying process to controllably increase elongation deformation and decrease shear deformation that the materials suffered. The mechanical principle and drive and control method of pulsating volume deformation injection machine (PVDIM), the characteristics of complex transport process of PVDIM, and the response law of the service properties of the polyester products to PVD will be studied. A complete set of PVDIM for polyester will be developed. The theoretical system of transport dynamics of plasticizing and conveying process in PVDIM and the theoretical system of mechanism design for PVDIM will be established. They will provide quantitative guidance for the effective control of plasticizing and conveying process in PVDIM for polyester and polyester composites, and for the effective control of structure and properties of the products. The fundamental research on new method and machine for manufacturing polyester parts will play an important role in promoting the development of the rubber and plastic processing machinery in our country. Moreover, it will greatly enrich and develop the modern manufacture theory for rubber and plastic products and its applications in our country.

当前国内外普遍采用的聚酯制件螺杆注塑设备，由于注塑成型过程中剪切形变易造成温度场不均匀甚至产生局部高温，严重影响制件成型（尤其是群腔成型）精度及服役性能。针对这种影响聚酯制件精密成型与成性的共性问题，通过物料在塑化输运过程中其体积的周期性变化，承受的剪切形变减少、拉伸形变可控增加，实现制件的群腔精密注塑成型及其性能调控，同时研究物料体积脉动形变过程机械原理及驱动控制方法、聚酯体积脉动形变的复杂传递过程特性、聚酯制件服役性能对体积脉动形变作用的响应规律，研制聚酯体积脉动形变注塑成型成套装备，创建橡塑材料体积脉动形变塑化输运动力学及机械设计理论体系，为聚酯及其改性材料体积脉动形变塑化输运工艺及制件的结构性能有效控制提供定量依据。这种聚酯制件制造新方法及新装备的基础研究对促进我国橡塑装备的高端化发展具有极其重要意义，同时将极大地丰富和发展我国橡塑产品先进制造理论及其应用。

目前国内外普遍采用螺杆设备注塑成型聚酯制件，由于成型过程中剪切形变易造成温度不均匀甚至产生局部高温，严重影响制件成型（尤其是群腔成型）精度及服役性能。针对这些影响聚酯制件精密成型与成性的共性问题，首创体积脉动形变支配的偏心转子塑化输运方法及装置，使物料在塑化输运过程中发生周期性的压缩和释放，可控增加拉伸形变而减少其承受的剪切形变；研制了体积脉动形变注射装置，使物料在注塑全过程中受到脉动变形作用，降低注射充模阻力，减少制件内应力，最终形成聚酯体积脉动形变注塑成型成套装备，实现了高品质聚酯制件的群腔精密注塑成型。.针对物料体积脉动形变过程机械原理及驱动控制方法、聚酯体积脉动形变塑化注塑过程中复杂传递过程动力学以及聚酯制件服役性能对体积脉动形变作用的响应规律等科学问题，基于运动学、动力学以及工作特性模型，构建了偏心转子塑化输运系统几何拓扑结构参数化设计方法，并探明体积脉动形变支配的注塑过程幅频调控机制及其模腔内熔体状态响应；基于聚合物拉伸流变表征新方法，阐明体积脉动形变支配偏心转子熔融塑化输运过程及特性，并提出体积脉动形变支配的聚酯等复合体系熔融共混机理及相形态演变规律；系统研究了体积脉动形变支配下聚酯等复合体系多梯度渐进分散及物理增容等机理对复合材料结构与性能的影响，从而构建出聚酯及其复合材料体积脉动注塑成型制件“机械结构-成型工艺-微观结构-服役性能”间的内在关系。.本项目创建并发展了橡塑材料体积脉动形变塑化输运动力学及机械设计理论体系，为聚酯及其改性体系体积脉动形变塑化输运工艺及制件的结构性能调控提供定量依据。项目新方法及新装备的基础研究对促进橡塑装备的高端化发展具有极其重要的意义，同时将极大丰富和发展我国橡塑产品先进制造理论及其应用。