一、橡膠膠管擠出常見問題及處理方法
橡膠膠管簡稱橡膠管,是使用橡膠制成的膠管,一般是擠(ji)出(chu)成(cheng)型(xing)的(de),在實際生產(chan)中(zhong)可能(neng)因(yin)為原(yuan)材料(liao)選擇不(bu)(bu)當、生產(chan)操作不(bu)(bu)當,造成(cheng)擠(ji)出(chu)的(de)橡膠管出(chu)現質(zhi)量缺陷,常見的(de)問題有:
1、管坯粗細不均
導(dao)致管坯粗(cu)細不(bu)(bu)均(jun)的原因主(zhu)要有三個:膠料可(ke)塑性不(bu)(bu)一致或熱煉不(bu)(bu)均(jun),喂(wei)料不(bu)(bu)均(jun)、擠出速(su)度和牽引速(su)度配(pei)合不(bu)(bu)當。
通過(guo)嚴格控制膠料可(ke)(ke)塑(su)性并(bing)加強(qiang)熱煉工(gong)藝,喂料時(shi)保持均勻喂料,保證擠出(chu)與牽引(yin)速度配合一致,可(ke)(ke)有(you)效避免(mian)管坯出(chu)現(xian)粗細不均的問題。
2、膠層破裂
膠(jiao)料內部(bu)含有(you)雜(za)質、局部(bu)自硫(liu)、膠(jiao)料中混有(you)膠(jiao)疙瘩或其(qi)他硬物容易導致擠出(chu)膠(jiao)管出(chu)現膠(jiao)層破裂的問(wen)題。
加強膠(jiao)料(liao)清潔工(gong)作,嚴格控(kong)制生產工(gong)藝(yi)與條(tiao)件、謹防(fang)膠(jiao)料(liao)自硫,適當改(gai)進配方,進行濾(lv)膠(jiao)工(gong)藝(yi),避(bi)免擠出管坯膠(jiao)層破裂。
3、膠層起泡或出現海綿現象
膠料(liao)中水(shui)分含量或揮發物(wu)含量過多,膠料(liao)在熱(re)煉或喂料(liao)時夾入空(kong)氣,擠(ji)出(chu)機溫度太高,擠(ji)出(chu)機螺桿磨損嚴(yan)重造成推力不足等因素都容易導致擠(ji)出(chu)管坯膠層出(chu)現氣泡或海綿現象。
實際操(cao)作過(guo)程中,嚴格控(kong)制原材料(liao)質量、必要時(shi)(shi)可進行(xing)烘干處理,適(shi)當(dang)掌控(kong)熱煉工(gong)藝、保(bao)證喂料(liao)均(jun)勻、防(fang)止膠料(liao)在機內翻滾夾入空氣,適(shi)當(dang)控(kong)制擠出溫度,及時(shi)(shi)保(bao)養、檢修擠出機螺桿(gan),可緩解上述問題。
4、管壁薄厚不均
在實際生(sheng)產中,芯(xin)型偏位、膠(jiao)料(liao)溫度(du)不均容易造成擠(ji)出(chu)管坯管壁薄厚不均的問題出(chu)現。
及時準確校準芯型位置,保證膠(jiao)料熱(re)煉均勻并適當保溫,可有效避免(mian)管壁出現薄厚不(bu)均的問(wen)題。
5、管坯黏著
生產過程中冷卻(que)溫度不夠、隔離效果差或擠(ji)出(chu)后(hou)管坯擠(ji)出(chu)太緊容易出(chu)現管坯黏著的問題(ti)。
將(jiang)擠(ji)出后(hou)的(de)管(guan)坯機(ji)進行(xing)充分冷卻(que)、嚴格控制(zhi)停放時(shi)間,擠(ji)出時(shi)噴涂(tu)適量的(de)隔(ge)離(li)劑,擠(ji)出后(hou)的(de)管(guan)坯不能擠(ji)出太緊,可(ke)避免管(guan)坯黏著。
在實(shi)際生產(chan)中,擠(ji)出(chu)管(guan)(guan)坯質(zhi)(zhi)量直(zhi)接(jie)影響橡膠管(guan)(guan)成品(pin)品(pin)質(zhi)(zhi),橡膠制品(pin)廠家一定要根據實(shi)際需求嚴格控制原材(cai)料質(zhi)(zhi)量、及時(shi)掌握生產(chan)工藝參數(shu)與進程,避免擠(ji)出(chu)管(guan)(guan)坯出(chu)現(xian)質(zhi)(zhi)量缺(que)陷。
二、如何保證再生膠膠管順利擠出
生產制作(zuo)(zuo)橡膠(jiao)膠(jiao)管(guan)時,很多時候(hou)是使用再(zai)生膠(jiao)制作(zuo)(zuo)的(de),再(zai)生膠(jiao)制作(zuo)(zuo)膠(jiao)管(guan),擠出更容易出問題(ti),為(wei)了讓(rang)再(zai)生膠(jiao)膠(jiao)管(guan)順利(li)擠出,主要注意以下四個(ge)事項:
1、注意再生膠細度與雜質含量
橡(xiang)(xiang)膠(jiao)管(guan)屬于(yu)擠(ji)(ji)出(chu)型(xing)橡(xiang)(xiang)膠(jiao)制品,如果所用(yong)再(zai)生(sheng)(sheng)膠(jiao)細度太低或(huo)含有雜(za)質(zhi)(zhi),那么就會(hui)導致再(zai)生(sheng)(sheng)膠(jiao)膠(jiao)管(guan)無法順利擠(ji)(ji)出(chu)。一般情況(kuang)下,壁(bi)厚在(zai)3-5mm的橡(xiang)(xiang)膠(jiao)管(guan)需要(yao)使(shi)用(yong)60目以(yi)上的再(zai)生(sheng)(sheng)膠(jiao),壁(bi)厚在(zai)2mm以(yi)內的橡(xiang)(xiang)膠(jiao)管(guan)需要(yao)使(shi)用(yong)80目左右(you)的再(zai)生(sheng)(sheng)膠(jiao)才能保證擠(ji)(ji)出(chu)膠(jiao)管(guan)表面(mian)平滑光亮;在(zai)實際生(sheng)(sheng)產中(zhong)如果再(zai)生(sheng)(sheng)膠(jiao)中(zhong)含有雜(za)質(zhi)(zhi),即(ji)使(shi)是(shi)細小顆粒也會(hui)造成膠(jiao)管(guan)表面(mian)或(huo)內部殘次,因此(ci)再(zai)生(sheng)(sheng)膠(jiao)膠(jiao)管(guan)在(zai)選擇再(zai)生(sheng)(sheng)膠(jiao)時一定要(yao)特別關(guan)注(zhu)再(zai)生(sheng)(sheng)膠(jiao)的細度與雜(za)質(zhi)(zhi)含量(liang)。
2、注意再生膠可塑度
合適的(de)可塑(su)(su)(su)度(du)(du)是(shi)膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)順利擠出(chu)的(de)基礎條件,膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)不(bu)同(tong)膠(jiao)(jiao)(jiao)(jiao)層(ceng)部件對(dui)膠(jiao)(jiao)(jiao)(jiao)料的(de)可塑(su)(su)(su)度(du)(du)需(xu)(xu)求不(bu)同(tong),因此需(xu)(xu)要將(jiang)再(zai)生(sheng)膠(jiao)(jiao)(jiao)(jiao)塑(su)(su)(su)煉(lian)到(dao)(dao)一定(ding)可塑(su)(su)(su)度(du)(du)。在實(shi)際生(sheng)產中,橡膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)內層(ceng)膠(jiao)(jiao)(jiao)(jiao)的(de)可塑(su)(su)(su)度(du)(du)一般在0.15-0.35之(zhi)間(jian),鋼絲(si)纏繞膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)、編(bian)織(zhi)膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)對(dui)再(zai)生(sheng)膠(jiao)(jiao)(jiao)(jiao)的(de)可塑(su)(su)(su)度(du)(du)要求更(geng)低,控制在0.15-0.2之(zhi)間(jian);橡膠(jiao)(jiao)(jiao)(jiao)管(guan)(guan)(guan)外(wai)層(ceng)膠(jiao)(jiao)(jiao)(jiao)料可塑(su)(su)(su)度(du)(du)需(xu)(xu)要塑(su)(su)(su)煉(lian)到(dao)(dao)0.35-0.45之(zhi)間(jian),擦布(bu)膠(jiao)(jiao)(jiao)(jiao)可塑(su)(su)(su)度(du)(du)在0.5-0.55之(zhi)間(jian),填充膠(jiao)(jiao)(jiao)(jiao)可塑(su)(su)(su)度(du)(du)塑(su)(su)(su)煉(lian)到(dao)(dao)0.35-0.45。
使(shi)用再(zai)生(sheng)膠(jiao)(jiao)(jiao)制(zhi)備無(wu)芯編織膠(jiao)(jiao)(jiao)管(guan)(guan)或纏繞膠(jiao)(jiao)(jiao)管(guan)(guan)時采用半硫化,再(zai)生(sheng)膠(jiao)(jiao)(jiao)hy可(ke)塑度可(ke)以適當(dang)增(zeng)加。與原(yuan)膠(jiao)(jiao)(jiao)相比,再(zai)生(sheng)膠(jiao)(jiao)(jiao)流(liu)動性、可(ke)塑性更好,有些再(zai)生(sheng)膠(jiao)(jiao)(jiao)在(zai)使(shi)用過(guo)程中甚至無(wu)需塑煉;當(dang)這類再(zai)生(sheng)膠(jiao)(jiao)(jiao)與原(yuan)膠(jiao)(jiao)(jiao)并用生(sheng)產橡膠(jiao)(jiao)(jiao)管(guan)(guan),橡膠(jiao)(jiao)(jiao)制(zhi)品廠家需要將原(yuan)膠(jiao)(jiao)(jiao)充分塑煉后再(zai)與再(zai)生(sheng)膠(jiao)(jiao)(jiao)混煉。
3、再生膠熱煉時需要注意熱煉溫度
橡(xiang)膠(jiao)管所用(yong)膠(jiao)料(liao)熱煉(lian)時,開(kai)煉(lian)機前、后輥溫(wen)(wen)度(du)(du)存在(zai)差異,一般前輥溫(wen)(wen)度(du)(du)比開(kai)煉(lian)機后輥溫(wen)(wen)度(du)(du)要(yao)高(gao)5-10℃左右;再(zai)生(sheng)膠(jiao)與其他種(zhong)類的原膠(jiao)或再(zai)生(sheng)膠(jiao)并用(yong)生(sheng)產橡(xiang)膠(jiao)管熱煉(lian)時開(kai)煉(lian)機前、后輥溫(wen)(wen)度(du)(du)應結合兩種(zhong)膠(jiao)料(liao)加工溫(wen)(wen)度(du)(du)合理調(diao)整。
乳膠(jiao)(jiao)再(zai)生膠(jiao)(jiao)膠(jiao)(jiao)管膠(jiao)(jiao)料進行熱(re)煉(lian)時前(qian)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)可以(yi)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)65-70℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian),后(hou)(hou)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)60-65℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian);輪胎再(zai)生膠(jiao)(jiao)生產(chan)(chan)橡膠(jiao)(jiao)管熱(re)煉(lian)時前(qian)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)可以(yi)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)55-65℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian),后(hou)(hou)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)50-55℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian);丁腈(jing)再(zai)生膠(jiao)(jiao)生產(chan)(chan)耐油膠(jiao)(jiao)管,膠(jiao)(jiao)料熱(re)煉(lian)時開(kai)煉(lian)機前(qian)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)50-60℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian),后(hou)(hou)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)應控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)45-55℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian);三元乙丙再(zai)生膠(jiao)(jiao)生產(chan)(chan)橡膠(jiao)(jiao)管進行熱(re)煉(lian)操作時,開(kai)煉(lian)機前(qian)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)在(zai)(zai)(zai)65-75℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian),后(hou)(hou)輥(gun)(gun)溫(wen)(wen)(wen)度(du)(du)控制(zhi)(zhi)(zhi)在(zai)(zai)(zai)60-65℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian);丁基再(zai)生膠(jiao)(jiao)耐熱(re)膠(jiao)(jiao)管生產(chan)(chan)過程中,熱(re)煉(lian)時開(kai)煉(lian)機強溫(wen)(wen)(wen)度(du)(du)在(zai)(zai)(zai)60-70℃,后(hou)(hou)輥(gun)(gun)溫(wen)(wen)(wen)調整(zheng)至55-65℃之(zhi)(zhi)(zhi)間(jian)(jian)(jian)。
4、再生膠熱煉時嚴格控制熱煉操作工序
使用再生膠生產橡膠管時,不(bu)同(tong)用(yong)(yong)途的(de)膠(jiao)(jiao)(jiao)料(liao)需要分別進行熱煉(lian)(lian),熱煉(lian)(lian)時保證環境清潔(jie),避免雜質混入;熱煉(lian)(lian)輥距(ju)應控(kong)制在(zai)(zai)4-6mm,熱煉(lian)(lian)后(hou)的(de)再生膠(jiao)(jiao)(jiao)膠(jiao)(jiao)(jiao)料(liao)保持一定的(de)膠(jiao)(jiao)(jiao)溫及(ji)時擠出(chu),避免焦燒、自硫(liu)等問題出(chu)現;返(fan)回膠(jiao)(jiao)(jiao)摻(chan)用(yong)(yong)在(zai)(zai)膠(jiao)(jiao)(jiao)料(liao)中再次熱煉(lian)(lian)時摻(chan)用(yong)(yong)比例應控(kong)制在(zai)(zai)30%左右。
為保證(zheng)再生膠(jiao)生產的橡(xiang)膠(jiao)管(guan)順利擠出(chu)(chu),橡(xiang)膠(jiao)制品廠家還需要控制再生膠(jiao)膠(jiao)管(guan)配(pei)方中其他配(pei)合劑的質量(包(bao)括細度、雜質、水分含(han)量等(deng)等(deng)),合理設計再生膠(jiao)膠(jiao)管(guan)配(pei)方中各配(pei)合劑的種類與用量,注意熱(re)煉后膠(jiao)料的停放時間,擠出(chu)(chu)時熱(re)煉膠(jiao)的輸送距離(li)等(deng);如(ru)果橡(xiang)膠(jiao)管(guan)加工廠家選擇(ze)冷喂料擠出(chu)(chu)機擠出(chu)(chu)擠出(chu)(chu)工藝(yi),再生膠(jiao)就(jiu)不(bu)必(bi)進行熱(re)煉工藝(yi)。