Computer Modeling for Single-Screw Extrusion of Wood–Plastic Composites

Wilczyński, Krzysztof; Buziak, Kamila; Lewandowski, A.; Nastaj, Andrzej

doi:10.3390/polym10030295

Cited by 35 publications

(33 citation statements)

References 57 publications

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“…Other computer models were developed by Fukase and Kunio [217], Zavadsky and Karnis [218], Vincelette et al [219], and Amellal and Lafleur [220]. Recently, Wilczyński et al [221] developed the computer program for simulating the single-screw extrusion of wood polymer composites.…”

Section: Computer Models Of Extrusionmentioning

confidence: 99%

Fundamentals of Global Modeling for Polymer Extrusion

et al. 2019

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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.

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Section: Computer Models Of Extrusionmentioning

confidence: 99%

Fundamentals of Global Modeling for Polymer Extrusion

et al. 2019

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“…According to this model, two stages of melting are distinguished: melting by conduction in the partially filled region of the screw where the polymer granules are collected at the active screw flight and melting by energy dissipation in the fully filled region where the unmolten solid particles are suspended in the previously molten material ( Figure 1b). This basic model was later extended to non-conventional screw configurations [31,32] and extrusion of polymer blends and composites [56][57][58][59].…”

Section: Flood Fed Vs Starve Fed Extrusionmentioning

confidence: 99%

Optimization for Starve Fed/Flood Fed Single Screw Extrusion of Polymeric Materials

Nastaj

Wilczyński

2020

Polymers

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A novel computer optimization system for flood fed/starve fed single screw extrusion of polymeric materials has been developed. This coupled system allows us to optimize single screw extrusion both flood fed and starve fed. Optimization is based on process simulation which is performed using global extrusion model GSEM (Global Screw Extrusion Model). The process is optimized with the use of GASEO (Genetic Algorithms Screw Extrusion Optimization) procedures which were developed using Genetic Algorithms. An example of optimization of extrusion process parameters has been presented to maximize extrusion output and minimize specific energy consumption. Optimization has been performed in a unique and original way in a coupled manner when both modes of feeding were allowed. The studies have shown that the optimal process is extrusion with starving. In this case, the global objective function reached the highest value, and extrusion throughput was relatively high and specific energy consumption was minimal.

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“…Films, sheets, pipes, and various profiles are produced by the extrusion method. Simulation of the extrusion process allows us to study the influence of many parameters (such as geometrical, rheological) on the structure of the polymer melt and predict the final product [2]. It is very difficult to observe the processes occurring in the extruder channel, therefore one of the possible ways to control and determine the rational parameters of the entire extrusion process is mathematical modeling.…”

Section: Introductionmentioning

confidence: 99%

“…In this regard, in most published works, elastic effects are not taken into account and polymeric media are considered as shear-thinning fluids. The power law model is the most frequently used model for the rheological description of polymer solutions and melts, for example, [2,15,16].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Polymer Solutions in a Single-Screw Extruder

2019

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Single-screw extruders are the most common equipment used for polymer extrusion. The study of the hydrodynamics of a polymer melts flow in the extruder channel is the basis for modeling and understanding the extrusion process. In general form, the extruder includes a straight section with a screw installed in it. In this study, the three-dimensional mathematical modeling of the polymer solutions flow in the metering zone of a single-screw extruder is performed. The influences of the screw geometry (L/D 2 = 1 . . . 3) on the flow structure and the pressure drop are analyzed under a speed rotation up to 60 rpm. Aqueous solutions of 0.5% polyacrylamide (0.5% PAA) and 1.5% sodium salt of carboxymethyl cellulose (1.5% CMC) are considered as the working fluid. Appl. Sci. 2019, 9, 5423 2 of 12 the helical screw channel is unwound and considered as a flat rectangular channel [4,[17][18][19][20][21][22]. Thus, plane-parallel fluid flow in a channel of infinite width is considered instead of direct 3D modeling. Also, the principle of reversed motion is often used (tube rotation is considered at the fixed screw) [4,[17][18][19][20][21][22]. In all works, polymers are considered as shear-thinning fluid [4,[17][18][19][20][21][22].The main functional zones of the extruder are feeding (solids conveying), melting, and metering. The metering zone is the simplest for modeling in a single-screw extruder, since the flow laws of viscous fluids can be applied to the polymer melt flow [23]. In this zone, the polymer is completely molten [24]. Besides, it is the metering zone that determines the extruder performance [23].Work [4] describes a simple numerical method for solving the problem of the polymer melt flow in the metering zone of the single-screw extruder. The 2D mathematical model takes into account the presence of circulating motion, non-Newtonian behavior of the processed material, and heating of the polymer due to viscous dissipation.In [3,18,19,21,22,25], numerical solutions obtained in a 2D and 3D formulation are approximated by symbolic regression models. The heuristic approach for predicting the main characteristics of the polymer melts flow in the extruder channel is based on genetic programming. Speaking about the evolutionary computation in general, it should be noted that they, like any method using an element of randomness, do not guarantee the detection of a global extremum of the objective function (or optimal solution) for a certain time. Their main advantage is that they allow finding a "better" solution to a difficult task in less time than other methods.In contrast with the standard flat-plate model of the unwound screw channel (2D), this hydrodynamic problem is solved in a three-dimensional formulation in [17,26]. Authors of the papers consider mathematical modeling of the flow in the metering zone of a plasticizing extruder. The objective of the study was the melting of the polymer composition based on polyethylene.Work [27] presents the results of three-dimensional numerical simulation of the polymer mel...

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Computer Modeling for Single-Screw Extrusion of Wood–Plastic Composites

Cited by 35 publications

References 57 publications

Fundamentals of Global Modeling for Polymer Extrusion

Fundamentals of Global Modeling for Polymer Extrusion

Optimization for Starve Fed/Flood Fed Single Screw Extrusion of Polymeric Materials

Numerical Simulation of Polymer Solutions in a Single-Screw Extruder

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