Structure and process optimization of mine ultra-high molecular weight polyethylene idler and its abrasion resistance
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 retar-dant 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 equiv-alent 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 opti-mization 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 optimi-zation,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 test of PE-UHMW double resistance composite roller was carried out through bulk sampling.The average abrasion volume is about 0.21 cm3,which is only 30%of the limit value,which proves that the mechanical properties of the roller are excellent and the process is reliable.
ultra-high molecular weight polyethyleneidlerfinite element simulationoptimal designextrusion process
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