CAJ | 학술논문

环模制粒成型技术以其高效率、高成型率、低污染等优点广泛应用于饲料机械、生物质能源机械、化工、制药等领域，而环模制粒过程扭矩模型的缺失已成为制约制粒技术发展的瓶颈之一。该文旨在通过理论分析、数值模拟与试验研究，建立粉体旋转挤压制粒成型过程精确扭矩模型，为粉体旋转挤压制粒成型装备的节能降耗及优化设计奠定理论基础。针对各向同性粉体物料，基于微单元受力分析及广义胡克定律，建立了旋转挤压制粒成型过程中模孔不同深度位置挤压压强的计算公式；基于DPC模型及实际辊轧工艺，建立了旋转挤压成型过程有限元分析模型，进行了压紧区应力分析；基于有限元模拟分析结果，设定变形压紧区的压强分布为二次曲线，建立了变形压紧区、挤压区的压强分布模型；最后建立了粉体旋转挤压制粒成型扭矩模型。以无线扭矩测试系统及环模制粒机为试验平台进行了鸡饲料的环模挤压制粒试验，求解得到了所有模型常量。设计了9组扭矩测试试验进行模型验证，测试结果与理论计算对比表明，试验值与计算值差距较小，最大计算误差仅为2.6%，这反映出建立的模型正确有效，对指导环模制粒机结构优化与节能降耗具有重要的意义。
배모제립성형기술이기고효솔、고성형솔、저오염등우점엄범응용우사료궤계、생물질능원궤계、화공、제약등영역，이배모제립과정뉴구모형적결실이성위제약제립기술발전적병경지일。해문지재통과이론분석、수치모의여시험연구，건립분체선전제압제립성형과정정학뉴구모형，위분체선전제압제립성형장비적절능강모급우화설계전정이론기출。침대각향동성분체물료，기우미단원수력분석급엄의호극정률，건립료선전제압제립성형과정중모공불동심도위치제압압강적계산공식；기우DPC모형급실제곤알공예，건립료선전제압성형과정유한원분석모형，진행료압긴구응력분석；기우유한원모의분석결과，설정변형압긴구적압강분포위이차곡선，건립료변형압긴구、제압구적압강분포모형；최후건립료분체선전제압제립성형뉴구모형。이무선뉴구측시계통급배모제립궤위시험평태진행료계사료적배모제압제립시험，구해득도료소유모형상량。설계료9조뉴구측시시험진행모형험증，측시결과여이론계산대비표명，시험치여계산치차거교소，최대계산오차부위2.6%，저반영출건립적모형정학유효，대지도배모제립궤결구우화여절능강모구유중요적의의。
Rotary roll extrusion pelleting technology is a kind of mainstream technology in the area of pellet forming technology, and the pellet mill has been widely used in the biomass-energy industry, feed industry, chemical industry, pharmacy, and so on. The pellet produced by the pellet mill has many advantages, such as a high forming rate, high absorption rate, high calorific value, and low pollution. But because of absence of the torque modeling theory, the existing pelleting technology with high consumption, low productivity, and low service life has been the bottleneck of industrial development. By a mathematical analysis, FEA simulation, and testing research, this paper aimed at developing an accurate torque model in the pelleting process of rotated roll forming. First, based on the unit force analysis and generalized Hooke law, the pressure distribution model along the die hole was founded. Then based on the DPC model and rolling processes, the FEA model of the pelleting process was created, and the stress distribution in the compacted zone was analyzed. Next, based on the results of the FEA, the pressure distribution in the compacting zone was set as aquadratic curve, and the pressure models in the compacting zone and extruding zone were built. Finally, the torque model in the ring-die pelleting process was developed. The experiments were designed to verify the model created, and the wireless torque testing system was used to analysis the torque datum. In order to eliminate the effect of the bending moment of the belt in pelleting process, two strain foils were stuck symmetrically along the same circumference of a shaft. The experimental material was chicken feed and the main components included Zea mays, wheat, bean, fish flour, bone flour, salt, and so on. The structural parameters of the pellet mill were as follows: the ring die radius was 175 mm, the number of rollers was 2, the ring die width was 110 mm, the die hole radius was 1.75 mm, the die hole length L was 35 mm, the percentage of the die opening area was 0.3, the roller radius was 80 mm, and the linear velocity was 6.1 m/s. When the pellet mill was in stability conditions, the torque data were tested in real time, and the average value in one minute was obtained as the torque value. At the same time, the pellets produced in one minute were collected and weighed to compute the volume of production. The tested results were as follows:the torque was 1 518.5 N·m, the production rate was 5.1 t/h, and the constant PN0 was 3.79 kPa. Based on the tested datum, all the model constants were determined and the torque model was developed. In order to verify the torque model, calculations and experiments were carried out in three other different linear velocities. It was shown that the computing datum was very close to the experimental results and the calculation error was less than 3%. The research was helpful to optimizing the structure, reducing energy consumption, and using the pellet mill efficiently.