Scribd
Upload
39 views3 pages

Towards The Design and Optimization of Twin-Screw Extruders - A Plasticating Modelling Program

This document summarizes a plasticating modelling program developed to simulate the processes that occur within co-rotating twin-screw extruders. The model sequentially simulates solids conveying, melting of a solid plug followed by melting of solid particles surrounded by melt, and melt conveying. The modelling routine accounts for differences between partially and fully filled flow channels. The program was tested using different operating conditions and screw configurations. As an example, melt temperature and pressure profiles along an extruder are shown. Validation of the model involves comparison with experimental measurements.

Uploaded by

Nam Nguyen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
39 views3 pages

Towards The Design and Optimization of Twin-Screw Extruders - A Plasticating Modelling Program

This document summarizes a plasticating modelling program developed to simulate the processes that occur within co-rotating twin-screw extruders. The model sequentially simulates solids conveying, melting of a solid plug followed by melting of solid particles surrounded by melt, and melt conveying. The modelling routine accounts for differences between partially and fully filled flow channels. The program was tested using different operating conditions and screw configurations. As an example, melt temperature and pressure profiles along an extruder are shown. Validation of the model involves comparison with experimental measurements.

Uploaded by

Nam Nguyen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 3

See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/261723296

Towards the Design and Optimization of Twin-Screw Extruders – A Plasticating


Modelling Program

Conference Paper · January 2006

CITATIONS READS

0 1,826

4 authors:

Rubens Faria Cristina Teixeira


Federal University of Technology - Paraná/Brazil (UTFPR) Portuguese Air Force
29 PUBLICATIONS   93 CITATIONS    9 PUBLICATIONS   68 CITATIONS   

SEE PROFILE SEE PROFILE

Antonio Gaspar-Cunha Jose Covas


University of Minho University of Minho
136 PUBLICATIONS   1,248 CITATIONS    248 PUBLICATIONS   3,353 CITATIONS   

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Mixing in Single Screw Extrusion View project

Deep learning image pattern recognition View project

All content following this page was uploaded by Cristina Teixeira on 21 April 2014.

The user has requested enhancement of the downloaded file.


Towards the Design and Optimization of Twin-Screw Extruders
– A Plasticating Modelling Program
R. Faria, C. Teixeira, A. Gaspar-Cunha, J.A. Covas
IPC – Institute for Polymers and Composites, Dept. of Polymer Engineering,
University of Minho, Campus de Azurém, 4800-058 Guimarães, Portugal

Abstract

The problem of defining the screw geometry of a co-rotating twin-screw extruder usually consists in
selecting a given number of individual screw elements from a wider available set and defining their
relative position in the screw axis. This may be assumed as an optimization problem aimed at improving
process performance, characterized by the presence of discrete decision variables, a very wide search
space and the eventual need to combine discrete and continuous decision variables (such as operating
conditions). The solving procedure must be capable of linking an optimization algorithm with a modelling
routine. Hence, the latter should be able to provide – with a minimum of computational requirements -
adequate process responses, not only in terms of the variety of the parameters considered, but also of their
values. The present work presents a plasticating model of co-rotating intermeshing twin screw extruders
(with the usual screw configuration including transport and mixing elements) developed with that
purpose, that covers sequentially solids conveying, melting of a moving solid plug followed by melting of
solid particles surrounded by melted polymer and melt conveying.

1 Introduction
Substantial experimental and theoretical work has been performed in order to understand the
physical, rheological and thermal phenomena involved in plasticating twin-screw co-rotating
extrusion. This enabled a progressively more complete and precise mathematical description of
the process, although some stages, such as melting, still require further investigation. Probably
due to this reason, software for plasticating twin screw extrusion is much rarer than for single
screw extrusion. This work aims at contributing to fill this gap.

2 Modelling Routine
The modelling routine developed takes into account (see Figure 1) solids conveying, melting
and melt conveying, a distinction being made between flow in partially and fully filled
channels.
It is well known that the presence of reverse elements and/or kneading blocks creates a
restriction to the flow and, as a consequence, a few transport turns upstream of these elements
become totally filled, their number depending on screw rotation frequency, output level and
geometry. The flow characteristics in partially filled / fully filled /t conveying sections / mixing
zones is also different.
Melting develops typically in less than a turn, as the material flows along the conveying element
upstream of the first restrictive zone. Initially, we consider the movement of a non-isothermal
solid plug with heat dissipation at all surfaces [1]. When the temperature near to the barrel
reaches the polymer melting temperature, a 5-zone melting model, similar to that adopted for
single screw extruders, is applied [2], i.e., the solid plug is considered to be surrounded by melt
films near to the barrel and screw root surfaces and by a melt pool near to the active flank.
When melting reaches 50%, we switch to a particle-dispersion melting model [3]. The evolution
of particle size is computed taking into account the increase in temperature of the particles by
conduction from the surrounding melt. Finally, melt flow in (fully filled portions of) the screw
and die is assumed as a 2-D non-isothermal flow of a non-Newtonian fluid [4].
Figure 1: Physical phenomena occurring inside of a co-rotating twin-screw extruder.

3 Case Study
The computer programme implemented was tested using different operating conditions (barrel
temperature profile, screw speed and feed rate) and screw configurations. As an example, Figure
2 shows the melt temperature and pressure profiles along a Leistritz LSM30.34 extruder
processing a polypropylene grade with the screws rotating at 150 rpm, the barrel set uniformly
at 250ºC and a feed rate of 10 kg/hr. Validation of these predictions involves direct comparison
with measurements performed in the actual machine.

Figure 2: Pressure and temperature profiles along a twin screw extruder.

5 References
1. Z. Tadmor and I. Klein, Engineering Principles of Plasticating Extrusion, Van Nostrand
Reinhold, Ney York (1970)
2. J.T. Lindt and B. Elbirli, Effect of the Cross-Channel Flow on the Melting Performance of a
Single-Screw Extruder, Polym. Eng. Sci, 25, pp. 412-418 (1985)
3. B. Vergnes, G. Souveton, M.L. Delacour and A. Ainser, Experimental and Theorectical
Study of Polymer Melting in a Co-rotating Twin Screw Extruder, Intern. Polym. Process., 16,
pp. 351-362 (2001)
4. R.T. Fenner, Principles of Polymer Processing, McMillan, London (1979)

View publication stats

You might also like