Numerical simulation of flow of rubber compounds in partially filled internal mixer

Abstract

Most numerical simulations of the flow in an internal mixer are based on the assumption that the internal mixer is totally filled with rubber compounds. However, in fact, the internal mixers are only partially filled with rubber compounds, thus posing many challenges for researchers in simulating the flow in the internal mixer. In this study, the volume of fluid method and the dynamic mesh technology of commercial CFD software FLUENT were used to simulate the flow of rubber compound in a partially filled internal mixer. To improve simulation accuracy, every 18 degrees in circumferential direction, we manually re‐meshed the calculated transient location of the rubber compound. Thus, we obtained the transient distribution of the rubber compound in the internal mixer as the rotors rotated. The simulation results showed that voids were mainly located behind the rotor blades, and there were material exchanges in the bridge regions between the two chambers. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015, 132, 42496.

Mixing ability examination of three different rotor cross sections and rotor geometry quantification with pressurization coefficient

“…The secondary flow was observed for three rotors, so the velocity gradient was quite larger at the tip, indicating strong shear rate. Besides, the secondary flow would benefit the material over the rotor tip, thus the material would go through the extensive mixing and elongational effect near the rotor tip . The velocity magnitude over the rotor tip for Type1 was larger than Type2 and Type3, demonstrating that the velocity gradient for Type1 was larger, and the material in flow would cross the rotor tip faster and easier.…”

“…Although, some works had been applied to study the effect of rotor cross‐section on mixing ability, but less works were published to rotor geometry quantification, which was very useful during the rotor cross‐section design and optimization. To fill this gap, three rotor cross section with different geometries were selected, and the mixing ability comparative study was performed under the assistant of POLYFLOW Software and online visualization system.…”

Numerical Optimization Simulation of Synchronous Four-Wing Rotor

“…The ultimate purpose of mixing is to achieve the refinement and uniform distribution of polymers and additives in a multi-component system through internal mixing equipment so that the various additives are completely and uniformly distributed in the rubber [ 3 ]. Such a process takes place in the mixer [ 4 ]. The rotor is the core equipment of the mixer, and its good performance is key for obtaining high-quality compounding rubber [ 5 ].…”

Continuous Preparation and Properties of Silica/Rubber Composite Using Serial Modular Mixing

“…Currently, industrial silica/rubber composites are generally prepared by batch mixing. The high shear effect provided by rotors reduces the viscosity of the mixture and disperses the filler in a raw rubber matrix [22,23,24,25,26]. A major problem with this method is that significant heat is produced by the rubber because of the high shear, which generates temperatures much higher than the silanization reaction can tolerate.…”