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    Computational Analysis and Design of Single Screw Extruders Having Screws of Complex Geometry With Mixing Elements

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    Xuan Phuong Huynh
    This document discusses computational modeling and design of single screw extruders with complex screw geometries and mixing elements. It provides a brief history of single screw extruder development and computational modeling efforts over the past 60 years. The challenges of modeling particle transport, melting of packed solid beds, and complex screw geometries are discussed. The current modeling approach uses modular models for each extruder section.

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    Computational Analysis and Design of Single Screw Extruders Having Screws of Complex Geometry With Mixing Elements

    Uploaded by

    Xuan Phuong Huynh
    44 views31 pages
    This document discusses computational modeling and design of single screw extruders with complex screw geometries and mixing elements. It provides a brief history of single screw extruder development and computational modeling efforts over the past 60 years. The challenges of modeling particle transport, melting of packed solid beds, and complex screw geometries are discussed. The current modeling approach uses modular models for each extruder section.

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    This document discusses computational modeling and design of single screw extruders with complex screw geometries and mixing elements. It provides a brief history of single screw extruder development and computational modeling efforts over the past 60 years. The challenges of modeling particle transport, melting of packed solid beds, and complex screw geometries are discussed. The current modeling approach uses modular models for each extruder section.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    44 views31 pages

    Computational Analysis and Design of Single Screw Extruders Having Screws of Complex Geometry With Mixing Elements

    Uploaded by

    Xuan Phuong Huynh
    This document discusses computational modeling and design of single screw extruders with complex screw geometries and mixing elements. It provides a brief history of single screw extruder development and computational modeling efforts over the past 60 years. The challenges of modeling particle transport, melting of packed solid beds, and complex screw geometries are discussed. The current modeling approach uses modular models for each extruder section.

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    of 31

    COMPUTATIONAL ANALYSIS AND

    DESIGN OF SINGLE SCREW


    EXTRUDERS HAVING SCREWS OF
    COMPLEX GEOMETRY WITH MIXING
    ELEMENTS
    John Vlachopoulos
    McMaster University
    Nick Polychronopoulos *
    Polydynamics, Inc.
    Shinichiro Tanifuji
    Hyper Advanced Simulation Laboratory (H.A.S.L.)

    SPE EUROTEC 2011


    BARCELONA, SPAIN
    The “heart” of every extruder is an
    ARCHIMEDEAN SCREW attributed to
    Archimedes 287-212 BC but, actually
    known to Egyptians for irrigation in the Nile
    Delta and the auger (screw drill) for
    carpentry was known to the Greeks before
    the 3rd Century BC.

    See:
    Chris Rorres, J.Hydraul.Eng., Vol.126, 71-80,
    (January 2000)
    SINGLE SCREW EXTRUDER:
    Rotating screw in a heated barrel.

    Early developments for rubber


    due to Thomas Hancock in 1820 in
    England.

    Modern developments started in


    the 1950’s.
    MODELING of EXTRUSION started in the
    1950’s
    Prominent names
    at DUPONT (USA) o Maillefer (parallel
    o McKelvey developments in
    o Gore Switzerland, 1950’s)
    o Squires
    1950’s
    - Maddock (Union Carbide) 1950’s
    - McKelvey’s book on P.P. appeared in 1962
    - The book by Z. Tadmor and I. Klein appeared in
    1970
    MODELING OF EXTRUSION IS 60 YEARS
    OLD, BUT MANY CHALLENGES REMAIN
    SINGLE SCREW EXTRUSION IS THE MOST
    COST-EFFECTIVE WAY TO MELT AND PUMP A
    POLYMER

    SCREW DESIGN calls for

    - OUTPUT MAXIMIZATION
    - MELT TEMPERATURE MINIMIZATION
    - EXTRUSION STABILITY
    - MELT QUALITY

    OPTIONS:
    - CONVENTIONAL single flighted screws
    - BARRIER screws
    - Screws with MIXING SECTIONS
    Conventional single screw (also
    called: plasticating) extruders are
    composed of three sections:
    In all screws at least the first 70% or so of
    melting is due to the shear stress in the
    melt film between the barrel and the solid
    bed surface.
    BARRIER SCREW PRINCIPLE

    - Increased melting.
    - At least 80% is melted by shear over
    the solid bed (i.e. very little conductive
    melting).
    MADDOCK (Union Carbide)
    MIXING SECTION
    CHALLENGES:
    SOLID PARTICLES TRANSPORT
    (pellets, size, properties, powders,
    difficult to describe mathematically
    particle flow)
    MELTING OF THE PACKED BED OF SOLID
    PARTICLES
    (how do solid particle properties affect
    the melting rate?)
    COMPLEX SCREW GEOMETRY
    (barrier screws, screws with various
    types of mixing elements)
    Our present modeling approach

    Current focus

    MODULAR, EASY TO UPGRADE MODELS FOR EACH SECTION


    DARNELL AND MOL (1956) MODEL

    BALANCE OF FORCES AND TORQUES


    MELTING (Tadmor’s Model)
    In the late 50’s, Bruce Maddock did experiments,
    pulling the screw and examining what happened.
    The conclusion was that MELTING REALLY OCCURS
    IN A FILM BETWEEN BARREL AND SOLID BED. A
    MELT POOL FORMS IN FRONT OF THE REAR
    FLIGHT, as shown:
    Metering section:
    We decided to use the Hele – Shaw
    flow approximation layer – by – layer
    2.5D analysis with 3D geometry
    Because our objective is screw design
    which means, simulation for a starting
    geometry, geometry upgrade…..till
    satisfactory results obtained.
    50 or more runs maybe need.
    “trial – and – error on the computer
    screen”.
    3-D NAVIER – STOKES for creeping
    non – Newtonian flow
    =
    0 = −∇P + ∇ ⋅ τ ∇ ⋅V = 0
    1  ∂Vi ∂V j 
     τ ij = f (eij ) i, j = 1,2,3
    eij = +

    2  ∂x j ∂xi 

    =
    ENERGY: ρ C PV ⋅ ∇ T = k ∇ T + τ : ∇ V 2

    HELE – SHAW FLOW APPROXIMATION


    ∂  ∂P  ∂  ∂P  h
    z 2 du
    S  +  S  = 0 S ( x, y ) = ∫
    ∂x  ∂x  ∂y  ∂y  o
    η ( x, y , z )

    S ∂P S ∂P ∂P z′dz′ ∂P z′dz′
    h h

    Vy ( z ) = − ∫ Vx ( z ) = −
    ∂x ∫0 η ( z′)
    Vx = − Vy = −
    h ∂x h ∂y ∂y 0 η (z′)
    =
    ENERGY: ρ C PV ⋅ ∇ T = k ∇ T + τ : ∇ V 3D
    2
    PLABOR JAPAN EXPERIMENTS
    Barrel Diameter = 40 mm

    5D 10D 12D
    FEED COMPRESSION METERING

    give measured value of pressure at


    both ends as boundary condition.
    predict pressure distribution /
    temperature distribution / extruder
    output
    Material：LDPE, Power-law approximation
    McMaster University Experiments
    - Single flighted screw, no mixing element
    - D=38 mm, L/D=24
    Material: HDPE (80 RPM)
    • FLOW RATE
    - Measured: 13.34 kg/hr
    - Predicted: 13.67 kg/hr
    • PEAK PRESSURE
    - Measured: 29.75 MPa
    - Predicted: 27.21 MPa
    --------------
    Somewhat better results for LDPE
    BRAMPTON ENGINEERING/McMASTER
    UNIVERSITY EXPERIMENTS CANADA

    - L/D=30, Diameter (D)= 88.9mm


    - 4 different screw designs
    - LDPE MI 0.3
    - LLDPE MI 1
    Experimental conditions
    • 16 runs performed: 4 screws x 2
    polymers x 2 output rates

    • Pressures measured at 8 locations


    along screw, plus at end of screw
    - values recorded once per second

    • Melt temperature measured at


    end of screw
    L/D=30, Diameter (D)= 88.9mm
    Barrier screw with Maddock
    Simulation

    Measurement
    Lagrangian melting particle simulation HDPE
    (Diameter of the initial solid particles: 5 mm)
    Lagrangian melting particle simulation HDPE
    (Diameter of the initial solid particles: 5 mm)
    Lagrangian melting particle simulation HDPE
    (Diameter of the initial solid particles: 2.5 mm)
    Lagrangian melting particle simulation HDPE
    (Diameter of the initial solid particles: 2.5 mm)
    THANKS
    Q&A

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