Modeling of Twin Screw Extrusion of Polymeric Materials

An issue of modeling of twin-screw extrusion of polymeric materials is reviewed. The paper is written in honor of Prof. James L. White who was a pioneer in studying this issue. A global approach to process modeling is presented which includes solid polymer transport, polymer plasticating, and the flow of molten polymer. The methodology of CFD modeling of twin-screw extrusion is presented as well as the examples of this modeling which show the details of the process. Optimization and scaling of twin-screw extrusion are also covered. And finally, the future prospects of developments and research of twin screw extrusion is discussed.

Fundamentals of Global Modeling for Polymer Extrusion

A review paper is presented on modeling for polymer extrusion for both single screw and twin-screw extrusion. An issue of global modeling is discussed, which includes modeling for solid conveying, melting, melt flow, and co-operation of the screw/die system. The classical approach to global modeling of the extrusion process, which is based on separate models for each section of the screw, i.e., solid transport section, melting and pre-melting sections, and the melt flow section is presented. In this case, the global model consists of the elementary models. A novel continuous concept of global modeling based on CFD (Computational Fluids Dynamics) computations is also presented, and a concept of using the DEM (Discrete Element Method) computation coupled with CFD computations is discussed.

Verifying the Melting Behavior in Single-Screw Plasticization Units Using a Novel Simulation Model and Experimental Method

We report on the development of a novel non-invasive ultrasonic measurement system for determining the melting behavior in a single-screw plasticization unit (35/22D) and on a modified drag-induced melt removal model that builds upon that by Tadmor and Gogos (2006). The solid bed to melt pool ratio is quantified using a non-invasive ultrasonic system based on reflection measurements. Automated analysis of the reflected pulses – measured at different axial positions along the barrel – allows the melting process to be monitored online. Our analysis of the delay section incorporates viscous dissipation into Tadmor's drag-induced melt removal model. We link temperature profile and melt film thickness via differential equations and consider viscous dissipation. By segmenting the delay section in the axial direction, the temperature dependency of the thermo-physical material properties is also considered. Using the melting behavior measured for different materials, we verified the mathematical model. Additionally, the effect of reduced screw length on the plasticization process, important for the injection molding process, was investigated.