Flow and Heat Transfer Along the Length of a Co-rotating Twin Screw Extruder

Teixeira, Cristina; Gaspar‐Cunha, A.; Covas, J. A.

doi:10.1080/03602559.2012.716477

Cited by 42 publications

(44 citation statements)

References 30 publications

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“…Due to its comparably low computational expense, it is still the only way to develop a simulation of the entire extrusion process. For more detailed information about 1D modeling, please refer to the literature, e.g., (White and Chen, 1994;Potente and Hanhart, 1994;Vergnes et al, 1998;Potente et al, 1999;White et al, 2001;Potente and Kretschmer, 2002;Prat et al, 2002;Choulak et al, 2004;Vergnes and Berzin, 2006;Bahloul et al, 2011;Teixeira et al, 2012;Eitzlmayr et al, 2014b).…”

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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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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“…20 A review on global modeling of screw processing has been presented by Teixeira et al 21 and Wilczynski et al 22 The main goal of this paper is to develop an integrated computer model for starve-fed nonconventional single-screw extrusion to predict the extent of filling, the pressure and temperature profiles, as well as the locations of melting. The Maddock mixing section has been used in the study.…”

Section: Mixingmentioning

confidence: 99%

A Global Model for Starve-Fed Nonconventional Single-Screw Extrusion of Thermoplastics

Lewandowski

Nastaj

Wilczyński

2015

Adv. Polym. Technol.

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ABSTRACT:A global computer model has been developed for starve-fed nonconventional single-screw extrusion. The model has been built by combining a new melt conveying model with recently developed melting models. Mixing screw equipped with dispersive mixing element of Maddock has been considered as an example for modeling. Extensive fully three-dimensional non-Newtonian Finite Element Method (FEM) computations have been performed to model the melt flow in mixing elements. Screw pumping characteristics have been computed and modeled for these elements at various power law indices. These characteristics have been implemented into the global model of the process. Computations were made for low-density polyethylene at various operating conditions. Fill factor, pressure, temperature, and melting profiles were simulated and validated experimentally. It has been confirmed by computation and experimentation that melting in starve-fed single-screw extruders is totally different compared with melting in flood-fed extruders. It is faster, and the screw length needed for melting extends with an increase of the flow rate. The screw is fully filled for some distance from the die only and starved beyond it. This distance is dependent on the flow rate and screw speed. C

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“…[1][2][3] Flood fed single-screw extrusion is generally well understood, and the literature is very rich here. [16][17][18][19] Wilczyński et al [15,20,21] first developed a mathematical model of fusion of polymers in starve fed single-screw extruders, and subsequently a composite model of the process, first for conventional screws, and later for non-conventional screws. [7][8][9][10] Starve fed extrusion process is much less known.…”

Section: Introductionmentioning

confidence: 99%

A computer model for starve‐fed single‐screw extrusion of polymer blends

Nastaj

Wilczyński

2017

Adv Polym Technol

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A new computer model has been developed to simulate a starve-fed single-screw extrusion process of polymer blends. This is a composite model, which is based on combining melt conveying models with new fusion models for polymer blends. The model is able to predict pressure and temperature profiles, filling of the screw and rate of polyblend fusion. Computer calculations were executed for extrusion of highdensity polyethylene and polystyrene blend at various technological conditions, and fill factor, pressure, temperature, and fusion profiles were calculated. The results of simulation studies were verified by experiment. K E Y W O R D S extrusion, modeling, polymer blendsHow to cite this article: Wilczyński KJ, Nastaj A, Wilczyński K. A computer model for starve-fed singlescrew extrusion of polymer blends. Adv Polym Technol.

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Flow and Heat Transfer Along the Length of a Co-rotating Twin Screw Extruder

Cited by 42 publications

References 30 publications

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

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

A Global Model for Starve-Fed Nonconventional Single-Screw Extrusion of Thermoplastics

A computer model for starve‐fed single‐screw extrusion of polymer blends

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