Helical flow of polymer melts in extruders, part 1: Model development

Sanjabi, Farshid; Upreti, Simant R.; Lohi, Ali; Ein‐Mozaffari, Farhad

doi:10.1002/adv.20195

Cited by 5 publications

(5 citation statements)

References 15 publications

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“…By varying the test parameters and recording the aforementioned sensor values in the roller cylinder, the measured data allow a validation of the simulation. Sanjabi et al have previously applied a similar validation approach based on pressure and temperature values for a single screw extruder [ 32 , 33 ].…”

Section: Methodsmentioning

confidence: 99%

Understanding the Dynamics of Polymer Extrusion: Simulation of Thermoplastics Processing with Planetary Roller Extruders

Radwan,

Schneider,

Müller

et al. 2024

Heliyon

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Section: Methodsmentioning

confidence: 99%

Understanding the Dynamics of Polymer Extrusion: Simulation of Thermoplastics Processing with Planetary Roller Extruders

Radwan,

Schneider,

Müller

et al. 2024

Heliyon

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“…The paper does not consider viscoelastic effects because of the complexity of the problem being solved. This assumption is quite common [34].…”

Section: Rheological Properties Of Polymer Solutionsmentioning

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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“…Several coordinate systems can be used to describe the flow along the helical screw channel. Calculations in helical coordinates have only been presented by a limited number of authors [ 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 ]; the main reason is that the governing flow equations in these coordinates are not very well established (see Section 7 ).

…”

Section: Modeling Fundamentalsmentioning

confidence: 99%

“…Several studies have used a helical coordinate system to analyze the flow of polymer melts in deep, curved screw channels [ 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 ]. Equivalent definitions of a non-orthogonal helical coordinate system were presented by Zamodits [ 27 ] and Tung and Lawrence [ 28 ]; while the former was applied to model curved extruder screws, the latter was used for static mixers.…”

Section: Curved Channel Systemsmentioning

confidence: 99%

“…Introducing further physical simplifications, Sanjabi et al [ 34 , 35 ] mathematically described the three-dimensional helical flow of a temperature-dependent power-law fluid in extruders. The governing flow equations, which additionally account for tapered screw sections, were first developed in cylindrical polar coordinates, and then transformed into a helical system.…”

Section: Curved Channel Systemsmentioning

confidence: 99%

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Melt Conveying in Single-Screw Extruders: Modeling and Simulation

Marschik¹,

Roland

Osswald

2022

Polymers

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Numerous analyses have modeled the flow of polymer melts in the melt-conveying zones of single-screw extruders. While initial studies mainly provided exact analytical results for combined drag and pressure flows of Newtonian fluids, more recently developed, numerical methods seek to deepen the understanding of more realistic flow situations that include shear-thinning and non-isothermal effects. With the advent of more powerful computers, considerable progress has been made in the modeling and simulation of polymer melt flows in single-screw extruders. This work reviews the historical developments from a methodological point of view, including (1) exact analytical, (2) numerical, and (3) approximate methods. Special attention is paid to the mathematical models used in each case, including both governing flow equations and boundary conditions. In addition, the literature on leakage flow and curved-channel systems is revisited.

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Helical flow of polymer melts in extruders, part 1: Model development

Cited by 5 publications

References 15 publications

Understanding the Dynamics of Polymer Extrusion: Simulation of Thermoplastics Processing with Planetary Roller Extruders

Understanding the Dynamics of Polymer Extrusion: Simulation of Thermoplastics Processing with Planetary Roller Extruders

Numerical Simulation of Polymer Solutions in a Single-Screw Extruder

Melt Conveying in Single-Screw Extruders: Modeling and Simulation

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