Comparison between 1D and 3D Approaches for Twin-Screw Extrusion Simulation

Durin, Audrey; Micheli, Pascal de; Nguyen, Hong Chau; David, Chantal; Valette, Rudy; Vergnes, Bruno

doi:10.3139/217.2951

Cited by 27 publications

(16 citation statements)

References 35 publications

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“…Todd [182] discussed the drag and pressure flows in twin-screw extruders. Recently, fully three-dimensional non-Newtonian FEM (Finite Element Method) computations were performed and the state-of-the-art tool was discussed by Ilinca and Hetu [163], Malik et al [183], and Vergnes et al [184] who compared the results of 3D simulations to the results issuing from the 1D Ludovic software. The 3D simulation method was found to be more accurate to describe flows in kneading discs, but the 1D model provided very satisfactory results for flows in screw elements.…”

Section: Melt Conveying Sectionmentioning

confidence: 99%

Fundamentals of Global Modeling for Polymer Extrusion

et al. 2019

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A review paper is presented on modeling for polymer extrusion for both single screw and twin-screw extrusion. An issue of global modeling is discussed, which includes modeling for solid conveying, melting, melt flow, and co-operation of the screw/die system. The classical approach to global modeling of the extrusion process, which is based on separate models for each section of the screw, i.e., solid transport section, melting and pre-melting sections, and the melt flow section is presented. In this case, the global model consists of the elementary models. A novel continuous concept of global modeling based on CFD (Computational Fluids Dynamics) computations is also presented, and a concept of using the DEM (Discrete Element Method) computation coupled with CFD computations is discussed.

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Section: Melt Conveying Sectionmentioning

confidence: 99%

Fundamentals of Global Modeling for Polymer Extrusion

et al. 2019

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“…For first principles simulations of the flow in co-rotating twinscrew extruders, mainly mesh-based CFD (computational fluid dynamics) methods, such as the FEM (finite element method) and FVM (finite volume method), have been used (e.g., Ishikawa, 2001;Bertrand et al, 2003;Malik and Kalyon, 2005;Ficarella et al, 2006a;Ficarella et al, 2006b;Kalyon and Malik, 2007;Barrera et al, 2008;Bierdel, 2008;Conzen, 2008;Rodríguez, 2009;Haghayeghi et al, 2010;Vyakaranam et al, 2012;Sarhangi Fard et al, 2012a;Sarhangi Fard et al, 2012b;Sarhangi Fard and Anderson, 2013;Hétu and Ilinca, 2013;Rathod and Kokini, 2013;Sobhani et al, 2013;Durin et al, 2014). FEM was also used to simulate complex fluids in extruders including wall slip phenomena, (e.g., Kalyon et al, 1999;Lawal et al, 1999;Malik et al, 2014).…”

Section: Introductionmentioning

confidence: 99%

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

Eitzlmayr

Khinast

2015

Chemical Engineering Science

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We applied SPH to study the flow in a co-rotating twin-screw extruder. A new model which accounts for the flow in unresolved clearances was presented. We showed detailed results for pressure drop, flow rate and power consumption. We achieved excellent agreement with CFD data for the completely filled state. Detailed results for the partially filled state are included. a b s t r a c tDue to the complex geometry of the rotating screws and, typically, free surface flows in partially filled screw sections, first principles simulations of the flow in co-rotating intermeshing twin-screw extruders using the well-established, mesh-based CFD (computational fluid dynamics) approaches are highly challenging. These issues can be resolved via the smoothed particle hydrodynamics (SPH) method thanks to its meshless nature and the inherent capability to simulate free surface flows. In our previous work, we developed a novel method for modeling the boundary conditions with complex wall geometries, under which SPH could be efficiently applied to complex surfaces of typical screw geometries of extruders. In this work, we employed SPH and our boundary method to study the flow in a conveying element in detail. To address unresolved clearances, we developed a new model that is coupled to SPH and can correctly account for the flow through unresolved clearances. A validation of our approach using CFD data from the literature for a completely filled conveying element indicated excellent agreement. Consequently, we studied the flow in a partially filled conveying element and obtained results for the flow rate, the power input and the axial force with variable filling ratio. A detailed analysis of the corresponding mixing phenomena is presented in Part 2. Our results show that the proposed method is a comprehensive approach to study the flow in different types of screw elements in detail, providing an excellent basis for further development of simplified models of entire extrusion processes.

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“…In the following, we shall drop the tensor-product indexing used in (8) and replace it by a single global index. As such, the mapping operator will be of the form…”

Section: Spline-based Meshing Techniquesmentioning

confidence: 99%

Boundary-conforming finite element methods for twin-screw extruders using spline-based parameterization techniques

Hinz

Helmig

Möller

et al. 2020

Computer Methods in Applied Mechanics and Engineering

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This paper presents a novel spline-based meshing technique that allows for usage of boundary-conforming meshes for unsteady flow and temperature simulations in co-rotating twin-screw extruders. Spline-based descriptions of arbitrary screw geometries are generated using Elliptic Grid Generation. They are evaluated in a number of discrete points to yield a coarse classical mesh. The use of a special control mapping allows to fine-tune properties of the coarse mesh like orthogonality at the boundaries. The coarse mesh is used as a 'scaffolding' to generate a boundary-conforming mesh out of a fine background mesh at run-time. Storing only a coarse mesh makes the method cheap in terms of memory storage. Additionally, the adaptation at run-time is extremely cheap compared to computing the flow solution. Furthermore, this method circumvents the need for expensive re-meshing and projections of solutions making it efficient and accurate. It is incorporated into a space-time finite element framework. We present time-dependent test cases of non-Newtonian fluids in 2D and 3D for complex screw designs. They demonstrate the potential of the method also for arbitrarily complex industrial applications.

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Comparison between 1D and 3D Approaches for Twin-Screw Extrusion Simulation

Cited by 27 publications

References 35 publications

Fundamentals of Global Modeling for Polymer Extrusion

Fundamentals of Global Modeling for Polymer Extrusion

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

Boundary-conforming finite element methods for twin-screw extruders using spline-based parameterization techniques

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