Mixing and Thermal Transport Behavior in a Pin or Non-Pin Extruder Equipped with a Field Synergy Elongation Screw

The ductile forming process of a polymer in a standard screw extruder and pin-barrel extruder, equipped with or without a field synergy elongation screw, was investigated by the finite element method. In order to assess the mixing and heat transfer capabilities of screws, characteristic parameters such as the mixing efficiency, segregation scale, and temperature distribution of different structures were analyzed and compared. The results indicated that the flow pattern of the polymer melt in the extruder was significantly influenced by the screw structure and was improved by the newly designed field synergy screw configuration, which brought a desirable elongational flow to enhance the radial convection. This was attributed to the unique radial wedge-shaped repeated convergence region of the field synergy elongation screw, increasing the synergistic effect between the velocity field, velocity gradient field, and temperature gradient field and thus improving the heat transfer and mixing efficiency. After adding barrel pins, the flow was forced to split, resulting in a more significant stretching effect on the melt. The field synergy effect in the pin mixed region was strengthened, which further increased the heat and mass transfer efficiency of the screw. However, increasing barrel pins could also lead to undesired temperature fluctuation and flow resistance, which have a negative impact on the melt uniformity. This study offers an important reference for optimizing screw structure to obtain strong mixing and heat transfer performances.