Chaotic mixing in a single‐screw extruder with a moving internal baffle

A geometry in which the mixing of a single‐screw extruder was enhanced by a reciprocating baffle is proposed in this article. The effect of the baffle's amplitude on the mixing kinematics of the screw channel was investigated. A model with the baffle lower than the screw channel and the corresponding mathematical model were developed. The periodic flow and mixing performance of Newtonian fluid in such an extruder were numerically simulated. The finite volume method was used, and the flow domain was meshed by staggered grids with the periodic boundary conditions of the barrier motion being imposed by the mesh supposition technique. Fluid particle tracking was performed by a fourth‐order Runge–Kutta scheme. Distributive mixing was visualized by the evolution of passive tracers initially located at different positions. The growth of the interface stretch of tracers with time and the cumulative residence time distribution were also obtained. Poincaré sections were applied to reveal the geometrical scale of chaotic mixing patterns and the regions with embedded regular laminar flows. For comparison, the mixing performance in a conventional single extruder with fixed baffle was also investigated. POLYM. ENG. SCI., 54:198–207, 2014. © 2013 Society of Plastics Engineers     

Mixing analysis of reactive polymer flow in a single‐screw extruder channel

In this study, the finite element method was used to investigate the influence of screw speed, entering peroxide distribution, pressure‐to‐drag flow ratio, and channel geometry on the mixing characteristics of steady non‐isothermal reactive flows. The reaction considered was the peroxide‐initiated degradation of a polypropylene resin in the metering zone of a single‐screw extruder. The predicted average degree‐of‐freedom profiles from the simulations largely conformed to expectations. The average flow efficiencies for all runs were found to vary little along the channel length, remaining at values close to that for two‐dimensional flow. No significant effect of either screw speed or peroxide distribution was found on the flow efficiencies. However, both the pressure‐to‐drag flow ratio and the channel aspect ratio were found to have significant influences.     

Beta phase in polypropylene induced by shear in a single‐screw extruder

The β‐phase in polypropylene (PP) induced by shear rate in a single‐screw extruder was studied. PP samples were extruded with and without a breaker plate at the exit of the extruder at five different screw rotational speeds: 20, 40, 60, 80, and 100 rpm. Differential scanning calorimeter was used to observe the melting behavior of the samples. The β‐phase was quantified by wide angle X‐ray diffraction. Extruded samples with a breaker plate showed higher values of β‐phase of PP than those extruded without a breaker plate. With a breaker plate, the maximum percentage of β‐phase was observed at 60 rpm (19.9%), whereas the maximum β‐phase content without breaker plate was observed at 40 rpm (13.6%). The higher level of β‐phase with the breaker plate was attributed to the shear rate induction and to the orientation by shear of the polymer chains through the orifices of the breaker plate. POLYM. ENG. SCI., 2012. © 2012 Society of Plastics Engineers     

Discrete particle simulations of solids compaction and conveying in a single‐screw extruder

This paper studies granular flow and compaction behavior of high‐density polyethylene by discrete particle modeling in order to gain greater understanding of the stress distribution within the solids‐conveying zone of a single‐screw extruder. The contact force–displacement model used in the simulations was first validated by simulating uniaxial compression in a batch compaction cell. Subsequently, the discrete particle approach was used to model in 3D the movement of particles within the solids‐inflow and solids‐conveying zone of a 32‐mm single‐screw extruder. Results of the simulations showed that axial pressure development did not increase in an exponential manner, as suggested by continuum models, largely due to the compressibility of the solids. The nature by which pressure developed was shown to be further complicated by the retarding frictional forces of the granular bed, indicating Archimedean transport phenomena close to the feed opening when the head pressure was low and inadequate stress transmission occurred along the screw. In the cross‐channel direction, the anisotropic stress field predicted found that the highest pressure in the screw channel was located at the screw root, while the lowest pressure corresponded to the retreating flight. The results were subsequently discussed in comparison to available continuum models. POLYM. ENG. SCI., 48:62–73, 2008. © 2007 Society of Plastics Engineers     

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.     

Melting process and mechanism for vibration induced single‐screw extruder

The effect of a vibration force field on the melting process of an extruder is studied. It is shown that the mechanism for melting differs from conventional theory. Experimental studies of melting of low‐density polyethylene (LDPE) pellets in a vibration‐induced single‐screw (VISS) extruder show that melting is initiated on the inside of the barrel and the surface of screw. Models were developed that explain the melting mechanism in those regions. The melting at the surface of the screw is mainly initiated by frictional work on the pellets by the vibration and rotation of the screw. The melting action at the barrel is induced by a barrel temperature higher than the melting point and propagated by viscous dissipation heating of the melt film produced. The theory is supplemented by a calculation sample, which shows good agreement with experimental data obtained on a transparent barrel VISS (T‐VISS) extruder and a half‐open barrel VISS (H‐VISS) extruder with LDPE. The results of the experiment and calculation sample indicate that the introduction of vibration‐induced field can improve the melting capacity of extruder to a great extent. The present model enables the prediction of processing parameters for VISS extruders, from which the optimum operating conditions can be obtained. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 2504–2514, 2007     

Viscosity analysis of polypropylene‐kaolin composites measured using single‐screw extruder

Deviations between data for the apparent and true viscosity measurement are commonly observed in the rheological studies of thermoplastics. To validate the significance on the usage of these data on the processing side, filling analysis for the apparent viscosity and true viscosity of polypropylene‐kaolin (PP‐kaolin) composites was conducted by using CadMold® software on the dumbbell Computer Aided Design model for comparative purposes. The raw apparent viscosity data were generated from a single‐screw extruder by using different sets of die geometries. Bagley and Rabinowitsch corrections were implemented to get a corrected set of true viscosity measurements. It was found that the true viscosity curves are lower compared with the apparent viscosity curves of PP‐kaolin. By constructing the corresponding data from PP‐kaolin composite rheological results, it was discovered that the high viscosity of the apparent viscosity melt data has shown a large variation in the mold distributions filling temperature, reduces the total pressure loss and melt shear stress, and increases the melt velocity during mold filling. Although the corrections were made on the calculated results, however, the significance is relatively small and it does not prove the changes in the overall physical property of the composite. Therefore, correcting the data by using the Bagley and Rabinowitsch corrections is not necessary in mold‐filling analysis. J. VINYL ADDIT. TECHNOL., 20:275–283, 2014. © 2014 Society of Plastics Engineers     

Melting mechanism of a starved‐fed single‐screw extruder for calcium carbonate filled polyethylene

A study of starved‐fed single screw extrusion was initiated to understand the relation between its distinctive melting mechanism and the improved mixing capabilities attained during compounding of a calcium carbonate filler into HDPE. Experiments were carried out in a 63.5 mm single screw extruder, examining the effect of degree of starvation on a conventional and barrier feed screw. Interest was focused on the mixing/melting mechanism of starved‐fed solids‐conveying as it affects the size and number of filler agglomerates observed in the extrudate. The melting performance of both feed screws was examined using pressure and temperature measurements down the screw length as well as direct inspection of the polymer in the screw channel via rapid screw cooling. Both screws showed improved mixing quality with increased starvation.     

Dynamical modeling of chaos single‐screw extruder and its three‐dimensional numerical analysis

The Chaos Screw (CS) nonlinear dynamical model is proposed to describe the development of chaos in a single‐screw extrusion process and the model is verified by three‐dimensional numerical simulations. The only‐barrier channel is the unperturbed Hamiltonian system, which consists of two homoclinic orbits and nested elliptic tori of nonlinear oscillation in periodic (extended) state space. A periodically inserted no‐barrier zone represents a perturbation. For small perturbations, homoclinic tangle leads to the Cantor set near the homoclinic fixed point and elliptic rotations are changed into the resonance bands or KAM tori, depending on the commensurability of frequency ratio of the corresponding orbits. A finite element method of multivariant Q?1+PO elements is applied to solve the velocity fields and a 4th order Runge‐Kutta method is used for the particle tracing. The resulting Poincaré section verifies the proposed dynamical model, showing the resonance band corresponding to rotation number 1/3 under small perturbations. As the strength of perturbation increases, the Poincaré sections indicate wider stochastic regions in which random particle motions take place.     

Developing laminar morphology in higher‐viscosity‐ratio polyblends by controlling flow fields in a single‐screw extruder

The morphology of high‐density polyethylene (HDPE)/polyamide‐6 (PA‐6) blends with different melt‐shear‐viscosity ratios (VRs), prepared by combining a single‐screw extruder with a convergent die was studied. Two different screw geometries, metering and mixing screws, and three screw speeds, 20, 40 and 60 rpm, were evaluated to investigate their effects on the morphology of extruded ribbons. Two mixing screws with low and high shear intensity, respectively, were used. Both the geometry and speed of screw were found to have an important role in the morphological changes of the blends. In contrast to previous studies, the results shown in this work reveal that it is possible to develop a laminar structure of PA‐6 in an HDPE matrix with a VR larger than one by controlling the flow fields, through appropriately combining the type and shear intensity of the screw with its speed. A well‐developed laminar PA‐6 phase with an aspect ratio of about 100 was obtained under the optimum combination. Copyright © 2004 Society of Chemical Industry     

The effect of the feed section groove taper angle on the performance of a single‐screw extruder

A new mechanism is described that allows adjustment of the groove geometry in grooved feed extruders. This mechanism enables efficient, continuous and independent change of the groove geometry during the extrusion process. The patented solution of the activated grooved feed section enables one to change the number of grooves, taper angle and, connected with it, groove depth. The paper contains the graphical presentation of the selected results of experimental studies of autothermal extrusion of a medium density polyethylene in an extruder with the grooved feed section in which the groove taper angle, and thus groove depth, was changed during the extrusion process. The influence of changing the groove taper angle in the range from 0 to 5.236 × 10^?2 rad and screw speeds ranging from 177 to 279 rev/min on extruder output was studied. The energy efficiency of the extruder was studied as well.     

Solvent‐free polymer emulsification inside a twin‐screw extruder

Solvent‐free extrusion emulsification (SFEE) is new technique for a twin‐screw extruder to prepare submicron‐sized particles (100–500 nm) without using hazardous solvents. The particle size is reliant upon the thickness of striated lamellae, which can be monitored rheologically based on the viscosity change occurring at the SFEE process. The lamellae coarsening rate is predominantly affected by the interfacial energy of the system when a surfactant is added but shows stronger dependency on viscosity change when interfacial growth between the polymer and water phases is solely determined by the end‐groups conversion into carboxylate species. For this latter case, the dissolution of the sodium hydroxide species and the kinetics of end‐groups conversion prove to be rate‐limiting phenomena to generating thinner striated lamellae. Additionally, the ionic strength of the system is notably important to the viscosity response and particle size produced, particularly when surfactant is not added. © 2018 American Institute of Chemical Engineers AIChE J, 64: 2113–2123, 2018     

Flow patterns and mixing mechanisms in the screw mixing element of a co‐rotating twin‐screw extruder

Non‐Newtonian and non‐isothermal flow simulations based on 3‐D FEM were applied to a special and conventional elements of a twin‐screw extruder. The screw mixing element (SME), a kind of special element, was a distributive mixing promoter consisting of a standard screw profile with slots cut across the flight tip to increase leakage flow. The full flight screw (FF) and the kneading block (KB) were examined as conventional elements in order to contrast the mixing behavior with the SME. The accuracy of numerical results was verified by experimentally measuring pressure and temperature. Additionally, marker particle tracking analysis was carried out to evaluate the distributive and dispersive mixing. Using the above analyses, the following results were obtained: The pumping capability of the SME was smaller than that of the FF and was the same as for the KB. The SME suppressed heat generation and showed the lowest temperature distribution of the three elements. For distributive mixing, the SME showed the best performance judging from the mixing coefficient G, residence time distribution, and area stretch distribution based on a laminar mixing mechanism. A higher rotational speed achieved better distributive mixing performance. For dispersive mixing defined by stress distribution, the SME showed the second best performance next to the KB. It also showed better dispersive mixing performance with increasing rotational speed. The SME had the advantages of low heat generation and good distributive mixing.     

Balancing mechanical properties and processability for devulcanized ground tire rubber using industrially sized single‐screw extruder

Devulcanized ground tire rubber (DGTR) samples were produced using an independently developed industrially sized single‐screw extruder. The DGTR was further revulcanized to produce revulcanized DGTR (RDGTR) samples. The structure and properties of the produced samples were investigated via tests and characterization of sol fraction, crosslink density, Fourier transform infrared spectroscopy spectra, X‐ray photoelectron spectroscopy spectra, Mooney viscosity, curing characteristics, dynamic rheology, tensile properties, and surface morphology. The results demonstrate that the extruder can effectively break up crosslinked structure of ground tire rubber to achieve high devulcanization level (characterized by sol fraction and crosslink density), which is mainly associated with its moderate shear strength. The balance between mechanical properties and processability for the DGTR samples was analyzed. Lower ratios of main‐chain to crosslink scission and good processability (mainly characterized by modest Mooney viscosity) for the DGTR samples, and high tensile strengths and elongations at break for the RDGTR samples are obtained via appropriately combining the barrel temperature and screw speed. High quality DGTR sample with tensile strength and elongations at break of up to 11 MPa and 370%, respectively, is prepared under the conditions used in this work. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43761.     

Study on effect of filler loading on the flow and swelling behaviors of polypropylene‐kaolin composites using single‐screw extruder

Melt flow and extrudate swelling behavior of polypropylene‐kaolin (PP‐Kaolin) composites were investigated using a single‐screw extruder. Kaolin was mixed with polypropylene (PP) using a heated two‐roll mill at 185°C and the filler loading were varied from 5 to 30 wt %. Subsequently, flow behavior of the compounded formulations were evaluated through Melt Flow Index (MFI) measurement at various temperatures ranging from 190 to 230°C. The extrudate swelling ratio was also measured by using an image analysis instrument and software. It was proven that the MFI decreased with increasing loading of kaolin for test temperatures of 190 and 200°C. However, for temperatures exceeding 200°C, the MFI value rose slightly at 5 wt % of kaolin content then seemed to reduce as more kaolin was added. This is also detected in rheological measurement where the apparent visosity, η_app, appear to be lowered at 5 wt % loading of kaolin. Further increase in kaolin loading resulted in increasing value of the composites η_app. The swelling ratio decrease with increasing filler loading for composites below 20 wt %. However, at 30 wt % of kaolin content, the extrudate swelling ratio increased and noticeable blistered surface texture was observed on the extrudate surface. Furthermore, at this level of filler loading, shrinkage occurence due to the existence thermal gradient between the surface and the inner core of the extrudate caused void formation in the middle section of the extrudate. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Evolution of morphology and of chemical conversion along the screw in a corotating twin‐screw extruder

A new sampling device is used to perform near‐real‐time investigations of physical and chemical processes occurring inside a laboratory twin‐screw extruder. Polyamide‐6–ethylene propylene rubber (PA‐6–EPM) blending and styrene–maleic anhydride (SMA) imidation experiments are reported in terms of morphology development and evolution of the chemical conversion along the extruder, respectively. Comparison of the results obtained using this new technique with those of classical screw‐pulling experiments evidenced the potential erroneous conclusions than can be drawn from the latter. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 71: 135–141, 1999     

Chaotic volumetric transports in a single‐screw extrusion process

Volumetric material transports across distinct regions in the Chaos Screw (CS) system were described in terms of the volume‐preserving lobe dynamics. Kinematic properties of a spatially periodic Poincaré map were studied first with the volume‐ and orientation‐preserving two‐dimensional map, in order to provide mathematical frame works for analyses of manifold structures. The perturbed hyperbolic fixed point and the associated stable and unstable manifolds were obtained numerically. These manifolds form homoclinic tangles, and they divide the cross‐sectional area into three distinct regions: left, right, and outer. Six volumetric flow rates between the three regions were described in terms of the associated lobe dynamics. As the perturbation strength increases, representative flow rates between these regions were found to increase linearly as long as the fraction of no‐barrier zone is small.     

Behavior of fully filled regions in a non‐intermeshing twin‐screw extruder

Twin‐screw extruders are operated with sequential filled and partially filled regions in order to perform the required unit processes. Channel fill length, defined as the length of fully filled regions in an extrusion screw, is gaining importance as a design parameter because of its implications on residence time distribution, distributive and dispersive mixing, and also process stability. A detailed study—experimental and theoretical—of the behavior of fill lengths in response to operating conditions (throughput, screw speed) and screw geometry is presented in this paper. Mean residence times were also measured for each geometry and operating condition. The apparatus consisted of a non‐intermeshing counter‐rotating twin‐screw extruder (NITSE) with a transparent (acrylic) barrel, fed with corn syrup (Newtonian at room temperature). Fill length exhibits a nonlinear relationship with specific throughput (Q/N), with the slope increasing monotonously as the throughput Q increases at a given screw speed N. The mean residence time exhibits a strong linear relationship with inverse specific throughput and inverse fill length. A theoretical model was developed to predict the filled length based on pressure‐throughput relationships taken from literature for this system, and the predictions were found to agree very well with experimental observations.     

Effectiveness of a backward mixing screw element for glass fiber dispersion in a twin‐screw extruder

In the kneading of glass–fiber‐reinforced plastics by twin‐screw extrusion, the use of a backward‐mixing screw (BMS) element for melt mixing has been found to be effective in dispersing glass–fiber bundles. In this study, we use computational fluid dynamics (CFD) to investigate the mechanism for the effectiveness of BMS for glass fiber dispersion. CFD of BMS melt mixing revealed that there is high uniformity of transport in the direction of extrusion and efficient transportation occurs from low‐stress to high‐stress regions. These findings demonstrate that BMS melt mixing is highly effective at imparting stress to the overall resin passing through. In addition, there is a correlation between the incidence of nondispersion of glass–fiber bundles measured experimentally and the stress history minimum value. On the basis of the above factors, we propose a method for predicting the operating conditions in which the nondispersion of glass–fiber bundles is controlled. The operating conditions for controlling glass–fiber nondispersion can be determined for various different mixing elements and the possible production rate can be predicted. Predictions for the operating conditions were applied to BMS and a forward kneading disk element (FKD). The effectiveness of BMS for controlling glass fiber nondispersion is characterized for a broad range of operating conditions. POLYM. ENG. SCI., 54:2005–2012, 2014. © 2013 Society of Plastics Engineers