26

2021-07

Calculation of kneader throughput

Total volume of the internal mixer - the volume of the cavity formed by the mixing chamber, side brackets (or retaining rings), discharge door, and pressure roller, minus the volume of the two rotors in the mixing chamber. It is the main parameter indicating the production capacity and is generally adopted according to series standards.

2021-07-26

26

2021-07

Open mill and closed mill mixing technology

I. Open Mill Mixing Technology The mixing process includes three aspects: Three processes: Open mill mixing can be divided into three stages: ① wrapping roller ② powder feeding ③ turning

2021-07-26

Open mill and closed mill mixing technology

05

2020-11

What precautions should be taken when using a two-roll mill?

What should be paid attention to when using a two-roll mill? A two-roll mill, also known as a plastic pressing machine, is mainly used for experimental pressing and color testing. Please pay attention to the following when pressing: 1. Do not allow the surface of the two rollers of the mill to be scratched by hard objects: Some manufacturers reuse materials, and there may be impurities in the materials, such as stones and iron filings. These must be cleaned up to avoid damaging the surface of the two rollers. If the surface of the roller is scratched, the pressed sheet will not be smooth and flat, affecting the color matching or testing. 2. There are skills in setting the temperature stability: Take 150 degrees as an example. When setting, do not set it to 150 degrees at once. This will increase the temperature quickly, but the stability will be slower. Start by setting it to 120 degrees, and then increase the temperature until it reaches 150 degrees, which will stabilize quickly. 3. Understand the forward, reverse, and emergency stop functions of the two-roll mill, and do not panic in an emergency. When using the mill, pay special attention to safety. In case of danger, immediately press the "emergency stop" or "roller reversal" button to stop the machine or reverse the rollers. 4. When the experiment is completed and the sample is taken, use wooden or bamboo products to remove the sample. Do not use metal products to scrape the surface of the two rollers to avoid damaging the surface. After the sample is made, clean the surface of the rollers with a cotton cloth and apply the appropriate protective oil to facilitate the next use. The temperatures of the two rollers of the mill are controlled separately. Set the appropriate temperature according to the needs to facilitate convenient, fast, flat, and smooth sheet making. The product structure is reasonably designed, and consumables are easy to replace. Buyers can replace them themselves. The machine has forward, reverse, and emergency stop functions to ensure the safety of the operator. This mill should be placed in a ventilated and dry place to extend its service life. Be sure to clean the two rollers of the two-roll mill. Generally, clean them with a cotton cloth and then apply machine oil to the surface for protection to facilitate the next use.

2020-11-05

22

2020-10

How to operate a kneader!

1. Calculate the single batch amount of rubber and the actual formula according to the capacity of the internal mixer chamber and the appropriate filling factor (0.6～0.7); 2. According to the actual formula, accurately weigh the amount of various raw materials in the formula. Place the raw rubber, small materials (ZnO, SA, accelerator, antioxidant, solid softener, etc.), reinforcing agent or filler, liquid softener, and sulfur separately and arrange them in order on the shelf; 3. Turn on the power switch and heating switch of the internal mixer for preheating. At the same time, check whether the air pressure, water pressure, and voltage meet the process requirements, and check whether the temperature measurement system, timing device, power system indication, and record are normal; 4. After the internal mixer is preheated, stabilize it for a period of time and prepare for rubber mixing; 5. Lift the upper top plug, put the raw rubber cut into small pieces into the internal mixer from the feeding port, lower the upper top plug, and mix the rubber for 1 min; 6. Lift the upper top plug, add small materials, lower the upper top plug and mix for 1.5 min; 7. Lift the upper top plug, add carbon black or filler, lower the upper top plug and mix for 3 min; 8. Lift the upper top plug, add liquid softener, lower the upper top plug and mix for 1.5 min; 9. Discharge the rubber, measure the temperature of the rubber with a thermocouple thermometer, and record the initial temperature of the mixing chamber, the temperature of the mixing chamber at the end of mixing, the discharge temperature, the maximum power, and the speed of the rotor; 10. Adjust the roll gap of the internal mixer to 3.8 mm, turn on the power switch to make the open mill run, open the circulating water valve, then put the rubber discharged from the internal mixer onto the open mill to wrap the roll. After the rubber temperature drops to below 110 ℃, add sulfur, cut twice with the left and right knives, wait until the sulfur is completely absorbed, the surface of the rubber is relatively smooth, and then cut off the rubber. 11. Adjust the roll gap of the internal mixer to 0.5 mm, put in the rubber for thin rolling, make a triangle package, thin roll 5 times, adjust the roll gap to about 2.4 mm, put in the rubber for roll wrapping. After the surface is smooth and bubble-free, take off the sheet, weigh the total mass of the rubber, place it on a flat, clean metal surface and cool to room temperature, paste a label indicating the rubber formula number and mixing date, and store it for later use.

2020-10-22

29

2020-09

Characteristics and advantages of kneading in an internal mixer

Characteristics of Internal Mixer Mixing Mixing rubber and various compounding agents in the high-temperature, high-pressure internal mixer mixing chamber, after a short period of kneading, dispersion, and mixing, the required mixed rubber can be obtained. The mixing process is: lifting the top ram → adding materials → lowering the top ram → pressurizing and mixing → mixing completion → opening the bottom ram → turning over → discharging → returning to the original position → closing the bottom ram. Advantages of internal mixer mixing: ① Short mixing time, high production efficiency, and good quality of mixed rubber; ② Large rubber loading capacity, high degree of automation of mixing and other operations, low labor intensity, and safe operation; ③ Small loss of compounding agents, less pollution, and clean workplace. Disadvantages of internal mixer mixing: ① The internal mixer is slow to dissipate heat, and the mixing temperature is difficult to accurately control. Materials sensitive to temperature are prone to scorching during mixing, and the cooling water consumption is large; ② The mixed rubber is in an irregular block shape and must be subjected to supplementary processing such as pressing; ③ Internal mixer mixing is not suitable for light-colored rubber, special rubber, rubber with frequent changes in variety, and rubber sensitive to temperature. Mixing Methods of Internal Mixer The mixing methods of internal mixers include one-stage mixing, two-stage mixing, feeding method, and reverse mixing method. (1) Working Stages of Internal Mixer Mixing Internal mixer mixing is divided into three stages: wetting, dispersion, and kneading. (2) BIT Value In the internal mixer mixing process, the wetting and dispersion stages play a dominant role. In production, the mixing performance of the rubber is often measured by the time required for the compounding agent to be uniformly dispersed in the rubber. Generally, the end time of dispersion is considered to be when the second power peak appears on the mixing time-power curve, which is called the Black Ink Time (BIT) value. The smaller the BIT value, the better the mixing performance of the rubber, i.e., the easier it is to mix. (3) Cooling and Standing a. Cooling is to avoid scorching and mutual adhesion caused by high temperature of the mixed rubber. Generally, it is cooled strongly to below 35℃. b. Standing allows the stress of the rubber molecules to relax, reducing shrinkage. It also allows the compounding agents to continue to disperse, and the carbon black and rubber to further combine, improving the physical and mechanical properties of the rubber. Rapid Inspection of Internal Mixers Controlling and ensuring the quality of mixed rubber is a key link in the production of rubber products. Rapid inspection is a rapid quality inspection of mixed rubber. The rapid inspection method is to take a sample from the front, middle, and rear parts of each batch of mixed rubber during sheeting, and determine its plasticity, vulcanization characteristics, hardness, tensile strength, elongation at break, permanent set, and density, and compare the measured results with the specified standard values to determine whether the quality meets the requirements. The inspection methods for the relevant items can be found in the corresponding national standards.

2020-09-29

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