Bulk solids are the raw material for almost every polymeric thermoplastic product. Their properties determine the quality of solids conveying and also influence the melting behavior of the material in processing units. This study investigates the influence of pressure and temperature on the bulk density of two thermoplastic polypropylene pellets of different shapes. Furthermore, the external friction dependent on temperature and pressure of those materials is examined at conditions usually occurring in the solids conveying zone of smooth barrel plasticating units. The experiments are carried out using a tribometer for polymer pellets which was adapted for these tests by making the sample chamber, the piston, and the cylindrical roll heatable. The tests show that long cylindrical pellets exhibit low bulk densities at low pressure and temperature, which can be increased dramatically-even above the values of spheroidal pellets-as those parameters increase. Moreover, the external coefficient of friction is always higher for the long cylinders and strongly dependent on the temperature. Those facts add up and can cause a higher output of single-screw extruders.
Summary: In single screw plasticizing technology dispersive mixing elements, i.e., axial and spiral Maddock shear heads, are often used to improve the melt quality. Mathematical models are necessary to efficiently design the mixing section. An analytical model for the design of Maddock mixers is presented in this work. In addition, a CFD‐software package is employed to determine the flow and pressure field for different geometries and processing conditions. For the design and process analysis of fluted dispersive mixers the validity and potential of simplified analytical solutions are compared to more versatile and detailed CFD‐simulations.
We report on the development of a novel non-invasive ultrasonic measurement system for determining the melting behavior in a single-screw plasticization unit (35/22D) and on a modified drag-induced melt removal model that builds upon that by Tadmor and Gogos (2006). The solid bed to melt pool ratio is quantified using a non-invasive ultrasonic system based on reflection measurements. Automated analysis of the reflected pulses – measured at different axial positions along the barrel – allows the melting process to be monitored online. Our analysis of the delay section incorporates viscous dissipation into Tadmor's drag-induced melt removal model. We link temperature profile and melt film thickness via differential equations and consider viscous dissipation. By segmenting the delay section in the axial direction, the temperature dependency of the thermo-physical material properties is also considered. Using the melting behavior measured for different materials, we verified the mathematical model. Additionally, the effect of reduced screw length on the plasticization process, important for the injection molding process, was investigated.
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