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.     

Modelling the solids inflow and solids conveying of single-screw extruders using the discrete element method

A new solids-conveying model for the single-screw extruder based on the Discrete Element Method (DEM) is proposed in this work. The polymer solids are treated as spherical particles moving in a 3-D environment which includes the feed hopper, the solids-inflow zone, and the solids-conveying region of an extruder, without inclusion of the plug flow assumption common to continuum models. Normal and tangential forces resulting from inelastic collisions with neighboring particles and surfaces dictate how each polymer pellet is conveyed through the model extruder. The DEM technique was implemented in this work to allow fundamental study of the local transport phenomena within the screw channel. Reported in this paper are results examining the cross- and down-channel velocity profile of solids in the screw; the residence time distribution; the cross-channel temperature profile; and the coordination number distribution. Two exit conditions were evaluated by the model: i) the open-discharge case where no compaction of the solids occurred; and ii) the restricted case where the axial pressure increased as the solids flowed towards the barrel exit. The predictions of the DEM simulations allowed for detailed observations of the solids movement in the screw, providing insight into the inherent flow fluctuations of extrusion systems.     

挤出加工方法对制备PP/PET原位微纤共混物微观形态的影响

分别使用双螺杆挤出机、配备不同结构螺杆或强剪切机头的单螺杆挤出机对聚丙烯(PP)/聚对苯二甲酸乙二醇酯(PET)进行熔融共混挤出,并用扫描电子显微镜观察了产物的微观形态。结果表明,使用双螺杆挤出机或使用配备三段式螺杆的单螺杆挤出机挤出PP/PET,只能制备出PET以球状形态均匀分散在PP连续相中的共混物,不含有任何微纤;使用配备有头部直槽混炼件的单螺杆挤出机挤出PP/PET,部分PET会形成短而粗的微纤;采用熔融挤出热拉伸淬冷法挤出PP/PET,可生产出微纤直径约为5 μm、长径比超过20的原位微纤共混物;采用强剪切机头及头部配备有直槽混炼件螺杆的单螺杆挤出机挤出PP/PET,可生产出微纤直径约为5~7 μm、长径比超过20的原位微纤共混物,且该方法操作简单、辅助设备少、具有工业可行性。     

Investigation of the poly(vinyl chloride) extrusion process using a feed throat with a feed pocket

The effectiveness of the extrusion process depends on a number of factors, the most important being barrel design, e.g., longitudinal or helical grooves; screw, feed opening, and polymer hopper designs are significant in this respect, too. The effect of these factors on the extrusion process has been thoroughly discussed in the available literature. This notwithstanding, there is little information providing insight on the effect of a feed pocket made below the feed opening, on the side of the barrel toward which the screw rotates, on the main characteristics of the extrusion process. For the experiments, five special profile inserts with different feed pocket depths were made and then mounted in the extruder barrel equipped with a 25‐mm diameter screw. The extrusion of plasticized poly(vinyl chloride) (PVC) at the screw speed ranging from 30 to 150 rpm was investigated. Presented graphically as charts, the obtained results show the dependences of extrudate temperature, extruder screw torque, polymer output, power supplied to the extruder and conveyed by the polymer, unit energy consumption and energy efficiency on the feed pocket depth, and screw speed. It has been found that the feed pocket made in the extruder barrel has little effect on the course and effectiveness of plasticized PVC extrusion and does not worsen the studied properties of the received extrudate; yet, it should be taken into account to ensure the highest polymer output and lowest energy consumption. POLYM. ENG. SCI., 54:2037–2045, 2014. © 2013 Society of Plastics Engineers     

单螺杆挤出机挤出理论研究进展

论文回顾了单螺杆挤出机挤出理论发展史,并从固体输送、熔融、熔体输送和混合四个方面详细介绍了近十年来挤出理论的最新研究进展。在指出现有不足的同时,提出了单螺杆挤出机未来的研究方向。     

Numerical analysis of the temperature profile in the melt conveying section of a single screw extruder: Comparison with experimental data

The prediction and measurement off the developing radial temperature profile in a single-screw extruder is essential since excessive extrudate temperature and poor temperature uniformity at the die affect the quality of coextrusion and film/sheet extrusion processes. A finite-difference scheme is used to predict the development of the radial temperature profile in the metering section of a single-screw extruder for power-law fluids. A finite-element analysis of the flow around the screw-tip transposes this temperature profile onto an on-line temperature measuring device consisting of 10 thermocouples for a comparison of numerical results with experimental data on polycarbonates.     

单螺杆挤出机螺旋沟槽固体段产量的实验研究

在自制的测试仪上对单螺杆挤出机螺旋沟槽固体输送段的产量进行了实验研究,探讨了沟槽衬套、螺杆的结构参数,物料粒径大小及螺杆转速对单螺杆挤出机固体输送段产量的影响,同时将螺旋沟槽单螺杆挤出机与IKV挤出机固体输送段的产量进行了对比。实验研究表明：粒径越小,螺旋衬套沟槽越宽,固体输送段产量越高;螺杆螺距变化对挤出机固体输送段产量的影响很小;IKV直槽挤出机固体输送段的产量明显小于螺旋沟槽衬套挤出机的固体输送产量,而且随着转速的增加,趋势越明显。     

Effect of process variables on melt velocity profiles in extrusion process using single screw plastics extruder

Abstract

Single screw extruders are used to generate a continuous flow of molten polymer in many industrial polymer processes. The melt velocity profile as extruded is important in determining the properties of the final product and influences process related phenomena such as die swell and the onset of sharkskin. The factors that influence the velocity profile would be expected to be the melt temperature (this affecting the viscosity of the melt), the screw and die geometry, and the output rate from the extruder. In the present work a thermocouple mesh sensor coupled with a cooled stainless tube has been used to determine velocity profiles in melts exiting from the screw of a single screw extruder. The results show that the technique can be used successfully to determine velocity profiles in the extrusion process.

It was found that the main influence on the magnitude of the melt velocity was the extruder screw speed. Melt temperature, and hence melt viscosity, were found to have little effect on the velocity profiles measured. The flow in the centre of the duct was retarded slightly owing to the flow across the screw tip and no rotational component of flow was observed. The velocity profiles measured seemed to be reasonably stable, only small changes being observed in the velocity profiles as the melt flowed along a duct of uniform cross-section, although these changes were limited in nature. Die diameter and length had a limited effect on the velocity profiles generated, although the die entry angle did have a significant effect on the shape of the velocity profile at higher screw speeds.     

Estimation of the morphology development of immiscible liquid–liquid systems during single screw extrusion

A mathematical model to predict the evolution of the morphology of immiscible liquid–liquid systems in single screw extruders has been developed. The model computes the dimensions of the dispersed phase in the polymeric matrix, taking into account the stretching, break‐up, and coalescence phenomena. The corresponding routine was inserted in a process modeling software, describing the flow in a single screw extruder from hopper do die. The drop dimensions were computed along the melting and melt conveying zones. This enabled the study of the morphological evolution of a two‐phase liquid system in a single screw extruder, taking into consideration the effects of the material properties, operating conditions, and screw geometry. The limited experimental data obtained was generally in line with the theoretical predictions. POLYM. ENG. SCI., 2010. © 2010 Society of Plastics Engineers     

单螺杆挤出机螺旋沟槽固体段压力的实验研究

在自制的压力测试仪上对单螺杆挤出机螺旋沟槽固体输送段的压力进行了实验研究,探讨了螺杆转速,沟槽衬套、螺杆的主要结构参数以及物料的粒径大小对挤出机固体输送段压力的影响,同时将螺旋沟槽单螺杆挤出机与IKV挤出机固体输送段的建压能力做了对比.实验研究表明:螺杆转速、沟槽宽度对固体输送段压力影响较小;粒径越小,螺杆螺距越大,挤...     

The effect of melt viscosity on thermal efficiency for single screw extrusion of HDPE

In this work, a highly instrumented single screw extruder has been used to study the effect of polymer rheology on the thermal efficiency of the extrusion process. Three different molecular weight grades of high density polyethylene (HDPE) were extruded at a range of conditions. Three geometries of extruder screws were used at several set temperatures and screw rotation speeds. The extruder was equipped with real-time quantification of energy consumption; thermal dynamics of the process were examined using thermocouple grid sensors at the entrance to the die. Results showed that polymer rheology had a significant effect on process energy consumption and thermal homogeneity of the melt. Highest specific energy consumption and poorest homogeneity was observed for the highest viscosity grade of HDPE. Extruder screw geometry, set extrusion temperature and screw rotation speed were also found to have a direct effect on energy consumption and melt consistency. In particular, specific energy consumption was lower using a barrier flighted screw compared to single flighted screws at the same set conditions. These results highlight the complex nature of extrusion thermal dynamics and provide evidence that rheological properties of the polymer can significantly influence the thermal efficiency of the process.     

Dynamic behavior of a single screw plasticating extruder part I: Experimental study

The dynamic responses of a 2–1/2 inch single screw plasticating extruder and extrusion line were investigated. Step changes in screw speed, take-up speed, back pressure, and processing materials were used to determine the transient responses of barrel pressures, die pressure, melt temperature, and extrudate thickness. Dynamic responses of the entire extrusion line can be explained by the flow mechanism of the extruder and the logical properties of the polymer used. A capillary rheometer was also used to determine if it could simulate pressure responses in the extruder for screw speed changes. Results showed that capillary rheometer was helpful in estimating the short term pressure responses in the die.     

利用挤出成型法制备具有夹芯结构的三层特殊梯度材料

采用单螺杆挤出成型机和流线形挤出模具,通过高密度聚乙烯(PE-HD)和聚氧乙烯(PEO)的共混挤出,研究了自组装成型三层特殊梯度结构的可能性。实验中挤出成型机和模具的温度设定与生产PE-HD膜时的相同,通过赋予成型物一定的温度梯度AT,并迅速冷却固化定型,成功地制备了PE-HD在表层富集、PEO在断面的中心附近富集的三明治式三层特殊梯度相分离结构材料。并通过偏光显微镜和显微傅立叶变换红外光谱仪分析,明确了挤出成型过程中形成梯度结构的驱动力是由温度梯度引发的热扩散索雷特效应。     

Extrusion of non-newtonian fluids in a single-screw extruder with pressure back flow

The transport phenomena underlying the extrusion of non-Newtonian fluids in single-screw extruders is investigated numerically and experimentally. The viscosity of the investigated fluids is a strong function of the temperature and, for the non-Newtonian case, of the shear rate. Therefore, the governing equations of motion are coupled to the energy equation through the viscosity. The velocity in the down channel direction of the screw extruder is a result of both shear and pressure driven transport. The pressure acts in a direction opposite to that of the drag flow, and comparatively high pressures arise at the die in typical extruders. When a narrow die is used in the screw extruder, the pressure gradient in the down-channel direction becomes so large that the down-channel velocity near the screw root becomes negative in terms of the coordinate system fixed to the screw. The conventional marching schemes fail to simulate the fluid flow when the down-channel velocity becomes negative, since the downstream conditions are not known. Two different numerical schemes used to simulate the fluid flow in a single-screw extruder for this circumstance, which often arises when dies with high flow resistance are used and which is termed as pressure back flow in the literature, have been discussed. One scheme is based on including the down-channel thermal diffusion, making the problem elliptic, and the other scheme uses a different coordinate system. Both formulations are found to yield results that are fairly close. Experiments were also carried out to measure the pressures at three different locations in a single-screw extruder. The computed results were found to be in good agreement with the experimental results. The pressures at the die obtained numerically by treating the flow as isothermal are found to be lower than those obtained when the flow is treated as nonisothermal, indicating the strong influence of thermal transport in this problem.     

Numerical simulation of fluid flow and heat transfer in a single-screw extruder with different dies

In a plasticating screw extruder, a polymer melt forms in the melting zone of the extruder. Pressurization of the molten polymer takes place in the melting and the metering sections so that the melt can flow through the restricted passage of the die and assume a desired shape. In a melt fed extruder, the throughput is governed by the pressure rise over the entire length of the extruder. The pressure developed in the screw channel may also be employed in rapid filling of molds, such as those in injection molding. When the geometry of the screw, the barrel temperature, and the die are selected, a unique set of operating parameters arise for a particular flow rate or screw speed. In the present study, numerical and analytical methods are used to calculate the transport in the extruder and the pressure drop in the die. An iterative numerical method based on solving the equations of motion and energy in the screw channel and a correction scheme to couple the die with the screw channel is discussed. The numerical algorithm is capable of handling an arbitrary variation of the viscosity of the polymeric fluid with the shear rate and temperature. The results obtained by simulating the fluid flow in the screw channel are compared with available numerical and experimental results in the literature, indicating good agreement. The performance characteristics of the extruder, for chosen thermal boundary conditions and screw geometry, are presented for different die geometries and different fluids. The important considerations that arise in the numerical simulation of the extrusion process are also discussed.     

Infrared melt temperature measurement of single screw extrusion

An infrared temperature sensor has been used to provide real time quantification of the thermal homogeneity of polymer extrusion. The non‐intrusive sensor was located in the barrel of a single screw extruder, positioned such that it provided a measurement of melt temperature in the channel of the metering section of the extruder screw. The rapid response of the technique enabled melt temperature within the extruder screw channel to be monitored in real time, allowing quantification of the thermal stability of the extrusion process. Two polyethylenes were used in experiments with three extruder screw geometries at a range of screw speeds. Data generated by the infrared sensor was found to be highly sensitive to thermal fluctuations relating to the melting performance of the extruder screw. Comparisons made with an intrusive thermocouple grid sensor located in the extruder die suggested that the infrared technique was able to provide a similar level of information without disturbing the process flow. This application on infrared thermometry could prove highly useful for industrial extrusion process monitoring and optimization. POLYM. ENG. SCI., 55:1059–1066, 2015. © 2014 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers     

Theoretical analysis of residence time distribution functions and strain distribution functions in plasticating screw extruders

The residence time distribution (RTD) function in a single screw plasticating extruder was theoretically calculated. The calculation is based on the solids conveying, melting, and melt conveying models in extruders. The screw channel is divided into small axial increments and the path of each exiting fluid particle is followed from hopper to die. In addition to the residence times the total shear deformation or strain imposed on the fluid particles was also calculated. This together with the RTD function has led to the definition and calculation of the strain distribution function (SDF). This function is proposed for quantitative characterization of the mixing performance of screw extruders as well as other laminar mixers. Some simple idealized batch and continuous laminar mixers are analyzed in terms of the SDF. Finally, the effect of extruder operating conditions and screw design on the RTD and SDF were investigated by computer simulations.     

间断副螺棱结构对挤出机内混沌混合影响的数值模拟

建立了混沌单螺杆挤出机计量段展开螺槽的物理模型及数学模型,根据流体符合Carreau定律,借助Ployflow软件,采用网格叠加技术,对聚合物熔体在插有间断结构副螺棱螺槽内的流动进行了数值模拟分析,从统计学的角度结合粒子示踪技术以停留时间分布、分离尺度、混合效率及累计混合指数为指标来表征螺杆的混合性能。结果表明,当副螺棱间断次数多且高度略低于螺槽高时混沌单螺杆混合性能更好。     

The modeling of continuous mixers. Part I: The corotating twin-screw extruder

In many operations in polymer processing, such as polymer blending, devolatilization, or incorporation of fillers in a polymeric matrix, continuous mixers are used; e.g., corotating twin-screw extruders (ZSK), Buss Cokneaders and Farrel Continuous Mixers. Theoretical analysis of these machines tends to emphasize the flow in complex geometries rather than generate results that can be directly used (1–5). In this paper, a simple model is developed for the hot melt closely intermeshing corotating twin-screw extruder, analogous to the analysis of the single-screw extruder carried out in 1922 and 1928 (6, 7). With this model, and more specifically with its extension to the complete nonisothermal, non-Newtonian situation, it is possible to understand the extrusion process and to calculate the energy, specific energy, and temperature rise during the process with respect not only to the viscosity of the melt, but also to the screw geometry (location and number of transport elements, kneading sections and blisters, pitch, positive or negative, screw clearance, and flight width) and screw speed. To support the theoretical analysis, model experiments with a Plexiglas-walled twin-screw extruder were performed, in addition to practical experiments with melts on small- and large-scale extruders, with very reasonable results, In Part 2, the Buss Cokneader will be analyzed analogously.     

Processing of reinforced plastics using multi-screw compounders

Polymer modification by addition of reinforcing agents represents a popular means of increasing physical property values. The polymer matrix has been forced to accept up to 55 percent by weight of fibrous reinforcement and 80 percent by weight of powdered types in order to meet application requirements. These materials demand sophisticated mixing equipment which must provide extensive intake and conveying capabilities, polymer wetting of reinforcement, and dispersion of reinforcement. This process must also be conducted with controlled shear intensity and excellent temperature and residence time control in order to respect polymer thermal sensitivity and product requirements. The extrusion process is a proven economical method for incorporating reinforcements into polymer resins. Co-rotating intermeshing twin-screw extruders are particularly suited for these tasks. Positive conveying, self-wiping, and shear intensive mixing characteristics provided by the screw mechanism satisfy requirements of reinforcement compounding. This mechanism allows interruption of streamline flow which is needed to disperse both high and low aspect ratio reinforcing agents into a polymer matrix. Mathematical representation of the benefits of twin-screw extrusion (relative to single-screw) related to pumping and mixing capability have been developed based on the classical pressure flow continuity equation with proper selection of boundary conditions.