Optimization and Scale-Up for Polymer Extrusion

Abstract

A review paper is presented on optimization and scale-up for polymer extrusion, both single screw and twin screw extrusion. Optimization consists in obtaining a multidimensional space of process output variables (response surface) on the basis of an appropriate set of input data and searching for extreme values in this space. Scaling consists in changing the scale of the process according to specific criteria, that is, changing the process while maintaining the scaling parameters at a level that is as close to the reference process parameters as possible. It consists in minimizing the differences between the parameters characterizing the reference process and the resulting process. This may be obtained by using optimization techniques leading to the minimization of discrepancies between the parameters of scaled processes. In the paper, it was stated that optimization and scale-up based on process simulation are more effective than those based on experimentation which is time consuming and expensive. The state-of-the-art on extrusion process modeling which is the basis of optimization and scale-up has been presented. Various optimization techniques have been discussed, and the Genetic Algorithms have been identified as powerful and very efficient. Optimization and scale-up based on the process simulation using Genetic Algorithms have been broadly reviewed and discussed. It was concluded that, up to date, there is a lack of optimization studies on the counter-rotating twin screw extrusion, although the global models of this process are known. There is also a lack of process simulation-based scaling-up studies, both on the counter-rotating twin screw extrusion and on the starve fed single screw extrusion. Finally, development perspectives in this field have been discussed.

A Combined Experimental and Modeling Study for Pellet-Fed Extrusion-Based Additive Manufacturing to Evaluate the Impact of the Melting Efficiency

“…In the process of scaling down SSE, a reduction in the viscous dissipation was thus witnessed in our previous work. This could be made clearer upon comparing the melting profiles for micro-extrusion and conventional extrusion under typical operation conditions for each technique on its own [38], consistent with preliminary results [47]. We also put forward in our previous theoretical study that screw parameters such as the screw frequency and pitch angle and material parameters such as the power-law index influence the relative position of the final EAM melting point.…”

Zwiększanie skali procesu jednoślimakowego wytłaczania tworzyw polimerowych

“…Covas i Cunha [36][37][38] oraz Berzin i inni [39] przedstawili także koncepcje zwiększania skali procesu wytłaczania dwuślimakowego współbieżnego. Zagadnienia te zostały ostatnio podsumowane w pracy przeglądowej [40]. Proponowane zwiększenie skali procesu wytłaczania na podstawie technik ewolucyjnych polega na pozyskiwaniu danych na podstawie badań symulacyjnych procesu i następnie zastosowaniu odpowiedniej procedury ewolucyjnej (algorytmów genetycznych).…”

Proces wytłaczania jednoślimakowego z zastosowaniem dozownika − zwiększanie skali

“…Koncepcję zwiększania skali procesu wytłaczania jednoślimakowego w warunkach dozowania grawitacyjnego autor przedstawił we wcześniejszych publikacjach [43,44]. Przedmiotem niniejszego artykułu jest zwiększanie skali procesu wytłaczania jednoślimakowego z użyciem dozownika przy zastosowaniu algorytmów genetycznych i specjalnie opracowanego programu GASES ST.…”