Study On Mixing Mechanism And Experiment Of Rubber Continuous Final Mixer

Mixing is the core link in rubber processing.As the final link of rubber mixing process,final mixing has a decisive influence on the quality of rubber products.After a long period of development,the final mixing equipment mainly composed of internal mixer and open mill has been equipped with relatively perfect production technology,but there are still many unavoidable defects.In order to overcome the problems,a double-rotor forced feeding continuous final mixer and its system which is suitable for the master module of rubber serial continuous mixing experimental platform were developed.The integration of continuous master mixing and final mixing was achieved by connecting the continuous final mixing system with the master mixing module of rubber serial continuous mixing experiment platform.And it can achieve stable producing,low energy consumption,high efficiency and high quality for rubber continuous final mixing.The main work of this paper is as follows:(1)The dynamic rheological mechanism and the pre-crosslinking mechanism of rubber final mixing process were established.Through the study of polymer rheology and vulcanization kinetics,the relevant theories of rubber continuous final mixing were clarified.The mechanical response characteristics and viscoelastic behavior of rubber in continuous final mixing process were explained.The dynamic rheological mechanism of rubber final mixing process was established based on the dynamic viscoelastic inclusion function derived from linear viscoelastic theory and the analysis of dynamic rheological behavior of rubber.In addition,the reactions in rubber continuous final mixing process were analyzed from micro to macro,physical and chemical perspectives.The mechanism of vulcanization reaction in rubber final mixing process was established.(2)A new type of double-rotor forced feeding continuous final mixer suitable for rubber serial continuous master-mixing module and its complete set of equipment were developed.As the core of the final mixing system,the continuous final mixer was designed by optimizing the feeding mode and the final mixing rotor modules based on the experience of rubber continuous mixing technology.It has the characteristics of strong pertinence for continuous finalization,high efficiency and stability in production,flexibility for many formulations and low unit energy consumption.(3)The flow field of rubber continuous final mixer was simulated.In this paper,the finite element simulation software Poly Flow was used to simulate the pressure field,shear rate field,viscosity field and mixing index of each final mixing module on the double rotors of the continuous final mixer.The data analysis proves its adaptability to continuous final mixing.(4)The experimental study on the changing process parameters of rubber continuous final mixing with the continuous final mixer was carried out,and the best final mixing process was determined.The influence of various process parameters of rubber continuous final mixer on rubber properties and energy consumption in final mixing process was investigated by setting several groups of control experiments.Through the analysis of the experimental results,the optimum process parameters of rubber continuous final mixer were determined as follows: double rotor speed is 30r/min,final mixing temperature is 60?70?.(5)The comparative study of rubber continuous final mixer,internal mixer and open mill was carried out to clarify the final mixing advantages of the three final mixing equipments.Through the experimental study,the continuous final mixer,internal mixer and open mill were compared and analyzed in terms of the final mixing compound quality,equipment energy consumption,production efficiency and so on.The experimental results show that the continuous final mixer has great advantages in production efficiency and unit energy consumption.For the carbon black formula,the unit energy consumption of the continuous final mixer is only 0.065 k Wh/kg,which is about 17% of the internal mixer and 15% of the open mill.For the white carbon black formula,the unit energy consumption of the continuous final mixer is only 0.082 k Wh/kg,which is about 22% of the internal mixer and 19% of the open mill.