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

Nastaj, Andrzej; Wilczyński, Krzysztof

doi:10.3390/polym12010149

Cited by 21 publications

(24 citation statements)

References 54 publications

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“…In addition, the processing advantages like limited die pressure fluctuations and a lower specific power consumption by starve-fed mode have been studied [ 8 ]. An optimization model for starve-fed single-screw extrusion showed that the optimized mode in a single-screw extruder in terms of specific energy consumption is starve-fed mode [ 9 ]. Recently Mazzanti showed the improvement in mechanical properties of rubber-toughened wood composites through starve-fed extrusion [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

Properties of Starve-Fed Extrusion on a Material Containing a VHMWPE Fraction

et al. 2021

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Single-screw extruders are usually operated with the screw fully filled (flood-fed mode) and not partially filled (starve-fed mode). These modes result in completely different processing characteristics, and although starve-fed mode has been shown to have significant advantages, such as improved mixing and melting performance, it is rarely used, and experimental studies are scarce. Here, we present extensive experimental research into starve-fed extrusion at feeding rates as low as 25%. We compared various operating parameters (e.g., residence time, pressure build-up, and melting performance) at various feeding rates and screw speeds. The results show a first insight into the performance of starve-fed extruders compared to flood-fed extruders. We explored starve-fed extrusion of a polyethylene material which contains a Very High Molecular Weight Polyethylene fraction (VHMWPE). VHMWPE offers several advantages in terms of mechanical properties, but its high viscosity renders common continuous melt processes, such as compression molding, ram extrusion and sintering, ineffective. This work shows that operating single-screw extruders in extreme starve-fed mode significantly increases residence time, melt temperature, and improves melting and that-in combination—this results in significant elongation of VHMWPE particles.

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Section: Introductionmentioning

confidence: 99%

Properties of Starve-Fed Extrusion on a Material Containing a VHMWPE Fraction

et al. 2021

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“…Chamil and colleagues developed an extruder melt temperature control with fuzzy logic [ 27 ]. Nastaj and Wilczynski in their work were able to optimize the single screw extrusion process using process simulations [ 28 ]. The process simulation technique was based on Genetic Algorithms Screw Extrusion Optimization procedures which have been developed using the Genetic Algorithm.…”

Section: Introductionmentioning

confidence: 99%

“…This technique was used to optimize both the starve and flood fed screw extrusion. The authors were able to conclude that the starving fed extrusion is optimal with a high extrusion output and low energy consumption [ 28 ]. Bingol and some of his colleagues developed an ANN model to predict the load for lateral extrusion.…”

Section: Introductionmentioning

confidence: 99%

Predicting extrusion process parameters in Nigeria cable manufacturing industry using artificial neural network

Adesanya

Abdulkareem

Adesina

2020

Heliyon

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The extrusion process is a very complex process due to the number of process parameters that are associated with it which are prone to high fluctuations. The main purpose of this work is to determine the realistic extrusion process parameters in the thermoplastic extrusion process in Nigeria cable manufacturing industries with the use of an artificial neural network. Conventionally, the use of trial and error technique which involves full-size experiments is generally used to determine the process parameters in the thermoplastic extrusion process. This conventional technique is expensive and it is also time-consuming. The use of an artificial neural network to predict extrusion process parameters before plant execution will make extrusion process operations more efficient. This technique also bridges the gap that exists between theoretical analysis and real manufacturing system because real manufacturers' data was used. The neural network was developed in a MATLAB environment and was trained with a supervised learning method based on Levenberg Marquardt Algorithm and the developed ANN model is capable of predicting manufacturing process parameters for different grades of PVC thermoplastic material.

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“…They called this mechanism the "hybrid melting mechanism" (HMM). Wilczyński et al [22,23,27,32,[35][36][37] observed the same mechanism when processing polymer Simplified schematic drawing of the contiguous solids melting mechanism (CSM) in the flat screw channel, adopted and adapted from Gogos and Tadmor [6]. W is the channel width and X is the width of the solid bed.…”

Section: Introductionmentioning

confidence: 99%

“…Wilczyński et al [22,23,27,32,[35][36][37] reported, that in starve fed SSE the polymer mixture is melted much faster via the DSM mechanism. Furthermore, Wilczyński et al [23] noted that "a melting model considering the presence of two materials is not currently (2017) available" and proposes applying "simply-structured mixing rules" for the calculation.…”

Section: Introductionmentioning

confidence: 99%

Melting Behavior of Heterogeneous Polymer Bulk Solids Related to Flood Fed Single Screw Extruders

et al. 2020

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Melting models for flood fed single screw extruders, like the Tadmor model, describe the melting of pure thermoplastic polymers. However, the melting behavior of heterogenous polymer systems is of great interest for recycling issues, for example. In this work, the melting of polymer mixtures and that of pure bulk polymers by the drag induced melt removal principle is examined both theoretically and experimentally. The applied model experiments represent the melting of the solid bed at the barrel in single screw extruders. As polymer pellet mixtures, polypropylene-homopolymer mixed with polypropylene-block-copolymer, high density polyethylene, polyamide 6, and polymethylmethacrylate were studied using different mixing ratios. The melting rate and the shear stress in the melt film were evaluated dependent on the mixing ratio. The results show that when processing unfavorable material combinations, both shear stress and melting rate can be far below that of pure materials, which was also confirmed by screw extrusion and screw pull-out experiments. Furthermore, approaches predicting the achievable melting rate and the achievable shear stress of polymer mixtures based on the corresponding values of the pure materials are presented.

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

Cited by 21 publications

References 54 publications

Properties of Starve-Fed Extrusion on a Material Containing a VHMWPE Fraction

Properties of Starve-Fed Extrusion on a Material Containing a VHMWPE Fraction

Predicting extrusion process parameters in Nigeria cable manufacturing industry using artificial neural network

Melting Behavior of Heterogeneous Polymer Bulk Solids Related to Flood Fed Single Screw Extruders

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