Melt Conveying in Single-Screw Extruders: Modeling and Simulation

Marschik, Christian; Roland, Wolfgang; Osswald, Tim A.

doi:10.3390/polym14050875

Cited by 8 publications

(4 citation statements)

References 126 publications

(208 reference statements)

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“…The issue of modeling the extrusion has been presented in books, for example, by White and Potente [ 23 ], Rauwendaal [ 26 ], Agassant et al [ 28 ], and has been reviewed in papers by Arrifin et al [ 32 ], Wilczyński et al [ 33 ], Teixeira et al [ 34 ], Malik et al [ 35 ], Wilczyński et al [ 36 ], Hyvärinen et al [ 37 ], Lewandowski et al [ 38 ] and Marschik et al [ 39 ].…”

Section: Introductionmentioning

confidence: 99%

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Wilczyński

Buziak

2022

Polymers

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Injection molding, in addition to extrusion, is the most important technology in the polymer processing industry. When modeling injection molding, the global approach is necessary to take into account the solid polymer transport, polymer melting and the polymer melt flow. The model of polymer melting is fundamental for the development of such a global injection molding model. In the paper, the state-of-the-art of modeling and experimentation of the flow and melting in injection molding machines has been presented and discussed. It has been concluded that the existing mathematical models have no strong experimental basis. Therefore, experimentation of the polymer flow and melting in the injection molding machine has been performed, and the effect of processing conditions: the screw speed, the plasticating stroke and the back pressure on the process course has been investigated. Starving in the beginning sections of the screw has been observed, which was not presented in the literature so far. The novel concepts of injection molding modeling have been discussed.

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Section: Introductionmentioning

confidence: 99%

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Wilczyński

Buziak

2022

Polymers

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“…the finite-volume method to calculate the target variables in Equations ( 10) and (11) for a given set of input parameters.…”

Section: Governing Equationsmentioning

confidence: 99%

“…The literature provides a few reviews that address the analysis of melt conveying and pressurization in single-screw extruders. [8][9][10][11] While the geometrical boundaries of the metering zone are fixed by screw design, polymer-melt flows can be found in multiple screw sections to varying extent. In the compression zone of a conventional screw, for example, solid and molten resin coexist side by side.…”

Section: Introductionmentioning

confidence: 99%

Extended melt‐conveying models for single‐screw extruders: Integrating domain knowledge into symbolic regression

Marschik,

Roland,

Kommenda

2023

Polymer Engineering & Sci

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The literature provides several analytical approximation methods for predicting the flow of non‐Newtonian fluids in single‐screw extruders. While these are based on various flow conditions, they were developed mostly for extruder screws with standard geometries. We present novel analytical melt‐conveying models for predicting the flow and dissipation rates of fully developed flows of power‐law fluids within three‐dimensional screw channels. To accommodate a broad range of industrial screw designs, including both standard and high‐performance screws, the main intention of this work was to significantly extend the scope of existing theories. The flow equations were first rewritten in a dimensionless form to reduce the mathematical problem to its dimensionless influencing parameters. These were varied within wide ranges to create a set of physically independent modeling setups, the flow and dissipation rates of which were evaluated by means of a finite‐volume solver. The numerical results were then approximated analytically using symbolic regression based on genetic programming. To support the regression analysis in finding accurate solutions, we integrated domain‐specific process knowledge in the preprocessing of the dataset. We obtained three regression models for predicting the flow and dissipation rates in melt‐conveying zones and tested their accuracy successfully against an independent set of numerical solutions.Highlights Flow of power‐law fluids in three‐dimensional screw channels Identification of independent influencing parameters by dimensional analysis Numerical parametric design study for a broad range of industrial applications Integration of domain knowledge in symbolic regression Surrogate models derived from numerical simulation results

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“…2024, 14, 220 2 of 20 only to improve the operating efficiency within the device, but also to improve the heat transfer efficiency between the device components [14][15][16]. As an illustrative instance, conventional screw extruders offer an insightful context for the examination of convective heat transfer efficiency [17][18][19]. The extrusion process in screw extruders necessitates the transfer of heat from a heater to the material via heat exchange within the extruder barrel, a fundamental step in achieving successful melt processing [20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experimental Research on Heat Transfer Characteristics Based on Internal Meshing Screw

Hao,

Guo,

et al. 2023

Applied Sciences

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The mixing and processing of high-viscosity materials play a pivotal role in composite material processing. In this context, the internal meshing screw mixer, rooted in volume extensional rheology, offers distinct advantages, including heightened mixing efficiency, exceptional material adaptability, and favorable thermomechanical properties. This research endeavors to advance our understanding of these qualities by presenting an in-depth exploration of internal meshing screw mixing. To facilitate this, an internal meshing screw mixing experimental apparatus was meticulously constructed, accompanied by extensive numerical simulations and experimental investigations into its heat transfer characteristics. Two distinct heat transfer modes are established: Mode 1 entails the transfer of the high temperature from the outer wall of the stator to the interior, while Mode 2 involves the transmission of the high temperature from the inner wall of the rotor to the exterior. The ensuing research yields several notable findings: 1. It is evident that higher rotational speeds lead to enhanced heat transfer efficiency across the board. However, among the three rotational speeds examined, 60 rpm emerges as the optimal parameter for achieving the highest heat transfer efficiency. Furthermore, within this parameter, the heat transfer efficiency is superior in Mode 1 compared to Mode 2. 2. As eccentricity increases, a corresponding decline in comprehensive heat transfer efficiency is observed. Moreover, the impact of eccentricity on heat transfer efficiency becomes increasingly pronounced over time. 3. A lower gap dimension contributes to higher heat transfer within the system. Nevertheless, this heightened heat transfer comes at the expense of reduced stability in the heat transfer process. 4. It is demonstrated that heat transfer in Mode 1 primarily follows a convection heat transfer mechanism, while Mode 2 predominantly exhibits diffusion-based heat transfer. The heat transfer efficiency of Mode 1 significantly surpasses that of Mode 2. This research substantiates its findings with the potential to enhance the heat transfer efficiency of internal meshing screw mixers, thereby making a valuable contribution to the field of polymer engineering and science.

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Melt Conveying in Single-Screw Extruders: Modeling and Simulation

Cited by 8 publications

References 126 publications

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Modeling and Experimental Studies on Polymer Melting and Flow in Injection Molding

Extended melt‐conveying models for single‐screw extruders: Integrating domain knowledge into symbolic regression

Numerical Simulation and Experimental Research on Heat Transfer Characteristics Based on Internal Meshing Screw

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