Modeling melt conveying and power consumption of co‐rotating twin‐screw extruder kneading blocks: Part B. Prediction models

Stritzinger, Ursula; Roland, Wolfgang; Berger‐Weber, Gerald; Steinbichler, Georg

doi:10.1002/pen.26249

Cited by 4 publications

(3 citation statements)

References 37 publications

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“…Investigations delve into various performance aspects, including melting efficiency, pressure and temperature profiles, viscosity considerations, and the influence of processing conditions and screw design. Researchers explore how parameters like screw speed, feed rate, profile, pellet size, and extruder size affect melting efficiency and effectiveness (Lewandowski & Wilczyński, 2022;Stritzinger et al, 2021). Pertanika J. Sci.…”

Section: Literature Reviewmentioning

confidence: 99%

Flow Analysis and Shear Rate Comparison of Counter-rotating and Co-rotating Intermeshing Twin-screw Extruders for Filament Extrusion of Polypropylene-based Biocomposites

Hidayat Syah Lubis,

Abdul Kudus,

Amran

et al. 2024

JST

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This study investigates and compares the performance of counter-rotating and co-rotating intermeshing twin-screw designs in filament extruder machines. The research sought to determine whether the counter-rotating intermeshing design with its opposite flow direction offers advantages over the co-rotating intermeshing design in terms of flow analysis and shear rates. Flow analysis was conducted to examine the velocity of the polypropylene-based biocomposite material inside the barrel. Shear rate data was obtained by evaluating the relationship between shear rate and screw speed to assess the stability and maximum shear rate of the twin-screw extruders. The results revealed that the counter-rotating intermeshing twin-screw extruders exhibited higher shear rates and more consistent pressure compared to the co-rotating intermeshing design. The superiority of the counter-rotating extruder was attributed to its opposite flow direction and distinct thread shapes, facilitating efficient material compression and improved dispersion of polymer-based biocomposite materials. The study suggested the potential for further exploration and refinement of the counter-rotating intermeshing twin-screw extruder design, particularly in producing polypropylene-based biocomposite filaments for Fused Deposition Modeling (FDM) machines.

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Section: Literature Reviewmentioning

confidence: 99%

Flow Analysis and Shear Rate Comparison of Counter-rotating and Co-rotating Intermeshing Twin-screw Extruders for Filament Extrusion of Polypropylene-based Biocomposites

Hidayat Syah Lubis,

Abdul Kudus,

Amran

et al. 2024

JST

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“…For a 30 mm extruder such mixing elements were investigated by Brouwer et al 25 The parametrization of different kneading blocks was investigated by Bauer using smoothed particle hydrodynamics simulations 26 and Stritzinger using a numerical modeling approach. 27,28 To calculate the mass balances for several species, the mass flows are multiplied by the weight fractions w i in each element. This formulation can be extended to the reactive case by including the reaction rate r i to take into account the weight fraction changes due to the chemical reaction:…”

Section: Mass Flow Modelmentioning

confidence: 99%

Optimal design and operation of reactive extrusion processes: Modeling, model validation, and optimization algorithm

Cegla,

Engell

2023

Polymer Engineering & Sci

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In this work, a methodology for the optimal design and operation of reactive extrusion processes in twin‐screw extruders is presented. As a process model, a very accurate mechanistic finite volume twin‐screw extruder model is used which is adapted to the reactive extrusion case. In the model, in contrast to other models, the pressure is described as a differential state in order to have a consistent set of equations. The model is compared to other models and advantages and disadvantages with respect to accuracy and computation time are discussed. For optimization, a memetic optimization algorithm (MA) that consists of a combination of a local optimization for the continuous operating parameters and an evolutionary algorithm (EA) for the global optimization of the discrete decision variables is employed to overcome the drawback of the longer model simulation time compared to simpler models. A reduction of optimization time by 90% for the MA compared to the EA was observed. The presented modeling and optimization methodology is validated on the widely investigated reactive extrusion process for ε‐Caprolactone. The methodology is very flexible and the underlying model has good prediction characteristics, thus it is applicable to a wide range of reactive extrusion processes of industrial interest.Highlights Simulation and optimization of reactive extrusion. Improved mechanistic twin‐screw extruder model. Novel approaches for pressure and residence time modeling. Efficient combination of local and global optimization in a memetic algorithm. Benchmarking of the optimization results and performance with literature data.

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“…In addition to determining the form of the fluid channel, the geometry of the screw element also impacts the direction and strength of the pressure flow at a specific flow rate and speed. High mixing capacity, good pressure accumulation, better flexibility and a large application range of the extrusion process can be obtained by the free combination and splicing of various types of screw elements [ 13 , 14 ].…”

Section: Introductionmentioning

confidence: 99%

Study on the Function of Conveying, Kneading Block and Reversing Elements on the Mixing Efficiency and Dispersion Effect inside the Barrel of an Extruder with Numerical Simulation

Wu,

Sun,

Zhang

et al. 2023

Foods

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In order to better understand the extrusion process mechanism of plant protein inside a barrel, the parameter changes and flow characteristics of fluids under conveying, kneading block and reversing elements were investigated with numerical simulation. The results showed that the shear rate increased obviously with the increase in pitch; the shear rate value of the reversing element was larger, while that of the kneading block was the opposite. The screw combinations of conveying, kneading blocks and reversing elements all have a certain degree of mixing effect on the particles, and the reduction in pitch can effectively increase the mixing effect of the particles. The conveying element can provide a relatively constant acceleration for the particles, due to the pumping capability and pressure buildup as the pitch increases. The kneading block and the reversing element can increase the leakage flow between the discs and backflow, resulting in an extension of the residence time distribution that facilitates fluid interaction in the barrel and improves the dispersion of the particles. The restraint by the reversing element on the particles is obviously weaker than that of the kneading block and shows a higher particle mixing degree. Overall, the influence of different elements on the flow condition, mixing degree and residence time is significantly different, which improves the process controllability and provides references for potential applications to meet multiple demands.

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Modeling melt conveying and power consumption of co‐rotating twin‐screw extruder kneading blocks: Part B. Prediction models

Cited by 4 publications

References 37 publications

Flow Analysis and Shear Rate Comparison of Counter-rotating and Co-rotating Intermeshing Twin-screw Extruders for Filament Extrusion of Polypropylene-based Biocomposites

Flow Analysis and Shear Rate Comparison of Counter-rotating and Co-rotating Intermeshing Twin-screw Extruders for Filament Extrusion of Polypropylene-based Biocomposites

Optimal design and operation of reactive extrusion processes: Modeling, model validation, and optimization algorithm

Study on the Function of Conveying, Kneading Block and Reversing Elements on the Mixing Efficiency and Dispersion Effect inside the Barrel of an Extruder with Numerical Simulation

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