矿用超高分子量聚乙烯托辊结构与工艺优化及耐磨性能  

Structure and process optimization of mine ultra-high molecular weight polyethylene idler and its abrasion resistance

作　　者：邱凤云 刘向东[1] 邱新伟 崔鹏 吴隆飞 智豪 QIU Fengyun;LIU Xiangdong;QIU Xinwei;CUI Peng;WU Longfei;ZHI Hao(School of Mechanical Engineering,Jiamusi University,Jiamusi 154007,China)

机构地区：[1]佳木斯大学机械工程学院,黑龙江佳木斯154007

出　　处：《工程塑料应用》2024年第12期73-82,共10页Engineering Plastics Application

基　　金：黑龙江省教育厅基本科研业务费人才培养项目(2021-KYYWF-0561)。

摘　　要：传统金属托辊用于带式输送机中存在诸多问题,如托辊与输送带之间磨损大、运行阻力大、自身质量大、使用寿命短、易损坏及密封性能差,这些问题在矿井等特殊环境更严重。为解决现有托辊问题,设计了一种新型超高分子量聚乙烯(PE-UHMW)复合材料托辊。选择PE-UHMW为基体材料,对其进行阻燃和抗静电改性,研制出一种PEUHMW双抗复合材料,用于制造矿用托辊产品。用ANSYS Workbench对PE-UHMW托辊和传统金属托辊进行静力学分析,有限元仿真结果显示PE-UHMW材料托辊在等效应力及质量上优于传统托辊,受力更安全,质量轻可降低运行阻力;然后改进并优化了PE-UHMW托辊结构,经多种方案对比,发现托辊辊筒内壁带圆形截面加强筋及圆环结构最优,弹性变形较小且受力均匀;通过响应面优化法得到加强筋的最佳尺寸为宽12.3 mm、高7.4 mm,圆环的最佳厚度为2.0 mm,优化后托辊应力较小,变形量较优化前减少了42.6%,质量与优化前相比变化不大,但比金属托辊减轻75%。设计了一体化挤出成型工艺,依据辊筒仿真结果设计挤出模具,并经正交试验选出了最佳工艺参数组合:机头温度为230℃、熔体压力为14 MPa、牵引速度为1.5 m/min,解决了PE-UHMW塑料挤出成型的难题。最后,通过本体取样对PE-UHMW双抗复合材料辊筒进行耐磨性能试验,其平均磨耗体积约为0.21 cm^(3),仅为极限值的30%,证明了辊筒力学性能优良,工艺过程可靠。The traditional metal idler used in belt conveyor has many problems,such as large wear between the idler and the conveyor belt,large running resistance,large weight,short service life,easy to damage and poor sealing performance,especially in special environments such as mines.In order to solve the problem of the existing idler,a new type of ultra-high molecular weight polyethylene(PE-UHMW)composite idler was designed.PE-UHMW was selected as the base material and modified by flame retardant and antistatic modification methods,and a kind of PE-UHMW double resistance composite was developed,which was used in the manufacture of mine idler products.The static analyses of PE-UHMW idler and traditional metal idler were carried out by ANSYS Workbench.The finite element simulation results show that the PE-UHMW idler is superior to the traditional idler in equivalent stress and mass,the force is safer,and the light weight can reduce the running resistance.Then,the structure of PE-UHMW idler was improved and optimized.By comparing various schemes,it is found that the structure of inner wall of the idler roller with circular section stiffener and ring is the best,and the elastic deformation is small and the force is uniform.By response surface optimization method,the optimum size of the stiffener is 12.3 mm of width and 7.4 mm of height,and the optimum thickness of the ring is 2.0 mm.After optimization,the stress of the idler is small,the deformation is reduced by 42.6%compared with that before optimization,and the mass is little changed compared with that before improvement,but it is reduced by 75%compared with the metal idler.The integrated extrusion molding process was designed,the extrusion mould was designed according to the roller simulation results,and the optimal combination of process parameters was selected by orthogonal test:the head temperature was 230℃,the melt pressure was 14 MPa and the traction speed was 1.5 m/min,which solved the difficult problem of PE-UHMW plastic molding.Finally,the abrasion resistance

关 键 词：超高分子量聚乙烯 托辊 有限元仿真 优化设计 挤出成型工艺 

分 类 号：TQ316[化学工程—高聚物工业] TQ320.73