Dynamic behavior of a single screw plasticating extruder part II: Dynamic modeling

The dynamic response of a 2.5 inch plasticating extruder and the extrusion line are modeled using high density polyethylene and acrylics us extrudate. Screw speed, back pressure valve position, and material changes are used as forcing functions. Three fundamental transfer functions in the Laplace domain: a first order, a second order, and a lead-lag, are developed to simulate the short term and long term responses of temperatures, pressures, and extrudate thickness. A kinetic-elastic model which can predict rheological properties of non-Newtonian, viscoelastic materials is also applied to the pressure responses of the extrusion process. This model can fit the experimental data well but due to the complexity involved in its parameter setting, more modifications are required before it can be applied for the control of extrusion process.     

Dynamic model of a plasticating extruder

A theoretical model for the simulation of dynamic operation of a plasticating extruder is proposed. The model can be recommended as a tool to study various dynamic situations of interest in the operation of an extruder. Several responses to changes in operating conditions are discussed. They indicate the occurrence of transient maximas and occasional oscillations. The controlling of flow rate by adjusting a valve at the die seems to cause temporary local high peaks in pressure, whereas its control through screw speed seems to be satisfactory.     

Experimental study of melting of polymer blends in a starve fed single screw extruder

Experimental study is presented of the melting mechanism of polymer blends in a starve fed single screw extruder. Various polyblends were investigated such as PP/PS, HDPE/PS, and PP/PMMA. “Screw pulling‐out” technique was used to study the solid conveying, melting mechanism, and extent of starvation. It has been concluded that melting mechanism consists of two stages: conductive melting in the starve fed region and dispersed melting in the fully filled region. Substantial differences between melting of neat polymers and polymer blends were observed. In the case of polyblends, in the starved region a mixture of two solid polymers is melted by conduction, and in the fully filled region a dispersion of one or two solid polymers in a molten matrix is observed. Although contiguous solids melting mechanism was not seen for starve fed extrusion of polyblends, it was clearly observed for flood fed extrusion. Melting action seems to be faster for starve fed extruders than for flood fed machines, since the polyblend granules are not compacted into a dense solid bed. It was observed the pressure considerably decreases with level of starvation. Filling of the screw increases with an increase of the feed rate of polyblend, and decreases with an increase of the screw speed. Global modeling of the starve fed single screw extrusion of polyblends has been discussed. POLYM. ENG. SCI., 56:1349–1356, 2016. © 2016 Society of Plastics Engineers     

A mathematical model for predicting dynamic behavior of a plasticating extruder

A mathematical model was developed to predict the dynamic behavior of flowrate and melt temperature in a plasticating extruder caused by changes in operating variables such as screw speed, back pressure and barrel temperature. The model has application for on-line computer control of an extrusion process or for simulation purposes off-line. Experimental data for developing the model was obtained from a 2½ in. diameter plasticating extruder producing high impact polystyrene sheet.     

一种往复运动的单螺杆挤出机

本文介绍的是一种螺杆往复运动的单螺杆挤出机,具有剪切均匀、高分散、高填充、拉伸熔体等特点。尤其是螺杆与机筒结构布局,齿轮箱往复运动的结构设计具有一定的特点。     

Numerical simulation of a single-screw plasticating extruder

A fully-predictive steady-state computer model has been developed for a single-screw plasticating extruder. Included in the model are a model for solids flow in the feed hopper; a variation of the Darnell and Mol model for the solids conveying zone; a variation of Tadmor's melting model for the melting zone; an implicit finite difference solution of the mass, momentum, and energy conservation equations for the melt-conveying zone of the extruder and die; and a predictive correlation for the extrudate swell at the die exit. A temperature- and shear-rate-dependent viscosity equation is used to describe the melt-flow behavior in the model. The parameters in the viscosity equation are obtained by applying regression analysis to Instron capillary rheometer data. Given the material and rheological properties of the polymer, the screw geometry and dimensions, and the extruder operating conditions, the following are predicted: flow rate of the polymer, pressure and temperature profiles along the extruder screw channel and in the die, and extrudate swell at the die exit. The predictions have been confirmed with experimental results from a 11/2 in. (38 mm) diameter, 24:1 L/D single-screw extruder with a 3/16 in. (4.76 mm) diameter cylindrical red die. High- and low-density polyethylene resins were used.     

Randcastle develops single screw compounding extruder

Randcastle Extrusion Systems, Inc. has developed a new compounding extruder. The company says that the Taskmaster is a single screw extruder that can compound and devolitilize. The Taskmaster is claimed to take single screw extruders into applications that were previously only possible with twin screw extruders. The prototype is a marked departure from Randcastle's vertical line of extruders with its first entry into the traditional horizontal extruder market.This is a short news story only. Visit www.addcomp.com for the latest additives and compounding industry news     

Identification of transient responses of a plasticating twin screw extruder due to excitation in feed rate

A corotating plasticating twin screw extruder (TSE) was excited by changing feed rate according to predesigned random binary sequence (RBS) and stair type excitation. A high density polyethylene was used as processing material in this study. Empirical models were developed relating two output variables, melt pressure at die (P_m), and melt temperature at die (T_m), with feed rate (F). Classical linear system identification technique was used to develop models. Models were developed using a data set obtained from RBS excitation. Stair type excitation data were used to validate the developed models. The structure of the obtained models was autoregressive moving average with exogenous input (ARMAX). Models with ARMAX structure and order of 2 were found to be sufficient to capture the dynamic behaviors of P_m and T_m when F was changed. A delay‐gain model was proposed for P_m and was found to capture the response quite satisfactorily. POLYM. ENG. SCI., 2011. © 2010 Society of Plastics Engineers     

Reactive processing of polyethylenes on a single screw extruder

The modification of low density polyethylene, linear low density polyethylene, and their blend by dicumyl peroxide at the time of the extrusion on a single screw extruder is reported. The study shows that the optimum conditions of modification can be determined on a torque rheometer and these can then be applied for actual extrusion. A low level of crosslinking can be introduced by reactive extrusion for improving the heat stability without adversely affecting the processing behavior. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2545–2549, 2001     

挤出机螺杆元件的国产化

中油吉林石化公司合成树脂厂ABS装置挤出机是从国外引进的关键生产设备,其螺杆元件十分昂贵,国产化问题日益突出。笔者介绍了挤出机的生产原理,分析了挤出机螺杆元件的材质特性,提出了国产化挤出机螺杆元件的材料选用和加工工艺,于2003年6月成功地实现了进口挤出机螺杆元件的国产化,为工厂节约了大量的资金。     

Residence time distribution in a real single screw extruder

The residence time distribution in an industrial single screw extruder was investigated experimentally in the case of melt and plasticating extrusion. The investigations performed proved that the extrusion parameters influence strongly the residence time distribution in the extruder. It was found that the resistance to flow through the die-head of the extruder is very important from this point of view, as well as other parameters like rotational speed of the screw and the screw channel depth. Variation of these parameters can change the residence time distribution over a broad range between the extreme idealized cases of plug flow and flow with perfect mixing. In order to obtain quantitative dependences three moduli were used and a correlation equation was obtained. This equation enables an estimation of residence time distribution on the basis of experimental characteristics of the extruder and the actual extrusion parameters.     

Modeling of the plasticating process in a single‐screw extruder: A fast‐track approach

A new mathematical model has been developed to analyze the entire flow field of a single screw extruder under steady‐state conditions. Intended as a rational design tool for practising engineers in the polymer processing industry, the model contains no partial differential equations and hence does not require the use of numerical solution techniques. To achieve generality, a generic approach is proposed and has been adopted in the derivation of governing algebraic equations from general conservation laws covering channel geometry, polymer flow speed, equivalent radius in a pipe, material properties, power consumption and heat transfer. The model makes no use of empirical factors or correlation. The validity of the new model has been assessed by comparison with published experimental results. Good agreement was achieved with respect to its ability to predict (a) the solid‐bed width profile; (b) the axial pressure profile and (c) the temperature and pressure of the melt pool at the extruder exit. Furthermore, the model can predict other information including the solid‐bed velocity in the axial direction and the power consumption. The work has demonstrated the potential of a fast track approach to designing helical extruder screws, while maintaining a level of accuracy comparable with more complex 3D models but without the penalty of computational efforts.     

Mixing studies in the single screw extruder

Laminar mixing in a single screw extruder between two miscible liquids is considered. Studies are presented which examine the mixing performance in single screw extruders with mixing sections, variable geometry screws, and multi-viscosity mixtures. Model extruders, set up on engine lathes, were used to mix colored silicone rubber which eventually cured in the screw channel. The cured silicone was then removed and sliced to measure the mixing. Results show mixing as a function of both down channel location and total average strain. For the mixing section study, results support the theory of interfacial area reorientation as the key mechanism in mixing section performance. Increasing viscosity ratio for the multi-viscosity study showed a decrease in mixing rate.     

On the dynamics and control of a plasticating extruder

In recent years, there have been many papers published on the application of process control to plasticating extruders. Much of the literature concentrates on the more classical control techniques. However, recent research has studied the application of stochastic identification techniques for building transfer function models for the extruder. In particular, the relationship of screw speed to die pressure and temperature has been studied. In the present work, both step tests and pseudorandom binary sequence tests were used to study the process dynamics of a 38 mm Killion extruder having a Iength-to-diameter ratio of 24:1. This study concentrates on the regulation of the extruder pressure in the face of its inherent surging characteristics. Variations in the quality of the feed plastic were studied through pulse and step changes in input polymer composition. Significant control problems resulted from measurement noise, which appeared at the same frequency as the screw rotation speed. Various mathematical filters to reduce the effect of this noise on the control variables were studied.     

On the scale-up of plasticating extruder screws

In the most commonly used scale-up method of plasticating extruder screws, the screw channel depth is increased by the square root of the diameter ratio while the screw RPM is decreased by the square root of the diameter ratio such that the output rate increases proportionally to the square of the diameter ratio. This scale-up method, largely based on the pumping function of the screw, often leads to a higher melt temperature, a higher screw horsepower consumption per unit output rate and an inferior melt quality from the larger diameter screw. Analysis of the common scale-up method reveals that, although the shear rate in the melt is kept constant, the average residence time and the peripheral screw speed are increased for the larger diameter screw. Our recent study on the melting mechanism also reveals that the melting capacity increases less than the pumping capacity. A detailed examination of the common scale-up method in this paper shows that the pumping capacity and the solid conveying capacity increase more than necessary while the melting capacity increases insufficiently.     

Optimisation of silane grafting in single screw extruder

Abstract

Reactive extrusion is an attractive means of polymer processing since the shaping and reaction takes place in a single operation. Silane grafting of low density polyethylene has been achieved in a single screw extruder. The optimum conditions for silane grafting, i.e. temperature, shear rate, and silane and dicumyl peroxide concentrations, were determined on a torque rheometer and extrusion was then performed under optimum conditions. The study shows that an optimum low level of grafting/crosslinking can be introduced into polyethylene during extrusion for better mechanical behaviour and/or thermal stability without aecting the processability.     

Studies on the theory of single screw plasticating extrusion. Part I: A new experimental method for extrusion

An extruder specially designed for the study of the single-screw plasticating extrusion process was constructed. Its barrel is equipped with glass windows which are located on both sides of it so that the full process of plasticating extrusion, solid conveying, melting, and melt conveying, can be clearly observed and recorded with photos and video recordings through the transparent windows. The solid profile X/W, the velocity of the solid bed V_sz, the forming positions of the upper melt film and the melt pool, and the position at which the break-up of solid bed occurs, was easily determined with good accuracy. Many dynamic characters of the plasticating extrusion, such as the non-plug solid conveying, the process of the break-up of the solid bed and the disappearance of the, broken pieces of solid, were also observed in the experiments.     

On modeling the solids conveying zone of a plasticating extruder

A model for the solids conveying zone of a plasticating extruder is presented. The flow of solid granules is studied in the framework of thermomechanics of media with affine structure, and assimilated to plane steady flow of an incompressible viscous fluid with spherical indeformable structure. Simple constitutive equations are accepted, along with those kinematical assumptions which stem directly from the geometry of the system. The resulting balance equations are given a dimensionless form, and integrated so as to arrive at closed-form solutions for velocity, spin and temperature of granules. A discussion of the influence of the adimensional parameters relevant to the problem is presented; this discussion is supplemented with some examples. Finally, various developments and refinements of the present model are proposed.     

An optimization approach to practical problems in plasticating single screw extrusion

Setting the extruder operating conditions, or establishing the adequate geometry of the screw, for a given group of specifications, is dealt with as an optimization problem where the solution is searched in a nonconvex space. In practice, this is a conflicting multi-attribute optimization problem, where various optima may coexist. The methodology developed involves the maximization of an objective function, quantifying the adequacy of the extruder-die combination response to particular inputs, whose values are computed using an extrusion modeling package developed for this work. Genetic Algorithms (GAs) are used to generate better sets of inputs. In a second stage, multi-objective optimization through Pareto curves, coupled to GAs, is implemented since, beyond optimization, it also provides a better understanding of the characteristics of the extrusion system under study.