Melting in a Single Screw Extruder: Experiments and 3D Finite Element Simulations
-
A. Altınkaynak
Abstract
The melting of an ABS resin was simulated using a three-dimensional finite element simulation of the two-phase flow in the compression section of a single-screw extruder. Screw freezing experiments were also conducted to compare the numerical predictions with the corresponding experimental data. Numerical simulations as well as experiments exhibited the Maddock melting mechanism and numerical predictions were in good agreement with the corresponding experimental data. The sensitivity of the melting profile to various material properties and processing conditions was numerically analyzed. With a constant flow rate enforced at the entrance of the screw channel, the screw and barrel temperature were found to have a minor effect on the melting profile. However, these parameters were found to have a significant effect on the predicted pressure profile along the screw channel. When the zero-traction boundary condition was imposed at the entrance of the screw channel, a change in the screw or barrel temperature affected the flow rate in the screw channel, which resulted in a significant change in the solid fraction at the same cross-section.
References
Agur, E. E., Vlachopoulos, J., “Numerical Simulation of a Single-Screw Plasticating Extruder”, Polym. Eng. Sci., 22, 1084–1094(1982), DOI: 10.1002/pen.760221706Suche in Google Scholar
Arnold, D. N., et al., “A Stable Finite Element for the Stokes Equations”, Calcolo, 21, 337–344(1984), DOI: 10.1007/BF02576171Suche in Google Scholar
Bathe, K. J.: Finite Element Procedure, Prentice Hall, Englewood Cliffs, New Jersey(1996)Suche in Google Scholar
Brooks, A. N., Hughes, T. J. R., “Streamline Upwind/Petrov-Galerkin Formulations for Convection Dominated Flows with Particular Emphasis on the Incompressible Navier-Stokes Equations”, Comp. Meth. Appl. Mech. Eng., 32, 199–259(1982), DOI: 10.1016/0045-7825(82)90071-8Suche in Google Scholar
Bruker, I., Balch, G. S., “Melting Mechanism in Single Screw Extrusion”, Polym. Eng. Sci., 29, 258–267(1989), DOI: 10.1002/pen.760290407Suche in Google Scholar
Campbell, G. A., et al., “Temperature Rise in a Single Screw Pump-Extruder”, SPE ANTEC Tech. Papers, 152–156(2001)Suche in Google Scholar
Campbell, G. A., et al., “Some New Observations Relative to Melting in Single Screw Extruders”, SPE ANTEC Tech. Papers, 213–217(2003)Suche in Google Scholar
Chiang, H. H., et al., “A Unified Simulation of the Filling and Postfilling Stages in Injection Molding. Part I: Formulation”, Polym. Eng. Sci., 31, 116–124(1991), DOI: 10.1002/pen.760310210Suche in Google Scholar
Chung, C. I., “A New Theory for Single-Screw Extrusion: Part I”, Modern Plastics, 45, 178–198(1968)Suche in Google Scholar
Cox, A. P. D., Fenner, R. T., “Melting Performance in the Single Screw Extrusion of Thermoplastics”, Polym. Eng. Sci., 20, 562–571(1980), DOI: 10.1002/pen.760200809Suche in Google Scholar
Cox, A. P. D., et al., “The Melting Behavior of a Low Density Polyethylene Powder in a Screw Extruder”, Polym. Eng. Sci., 21, 86–92(1981), DOI: 10.1002/pen.760210206Suche in Google Scholar
Dekker, J., “Improved Screw Design for the Extrusion of Polypropylene”, Kunststoffe, 66, 5–7(1976)Suche in Google Scholar
Donovan, R. C., “A Theoretical Melting Model for Plasticating Extruders”, Polym. Eng. Sci., 11, 247–257(1971), DOI: 10.1002/pen.760110313Suche in Google Scholar
Donovan, R. C., “Pressure Profiles in Plasticating Extruders”, Polym. Eng. Sci., 11, 484–491(1971), DOI: 10.1002/pen.760110607Suche in Google Scholar
Edmondson, I. R., Fenner, R. T., “Melting of Thermoplastics in Single Screw Extruders”, Polymer, 16, 49–56(1975), DOI: 10.1016/0032-3861(75)90095-6Suche in Google Scholar
Gale, G. M., “Dry-Blend Extrusion of Rigid PVC”, Plastics and Polymer, 38, 183–191(1970)Suche in Google Scholar
Halmos, A. L., et al., “Melting in Single Screw Extruders”, Polymer, 19, 1199–1216(1978), DOI: 10.1016/0032-3861(78)90072-1Suche in Google Scholar
Harari, I., Hughes, T. J. R., “Stabilized Finite Element Methods for Steady Advection-Diffusion with Production”, Comp. Meth. Appl. Mech. Eng., 115, 165–191(1994), DOI: 10.1016/0045-7825(94)90193-7Suche in Google Scholar
Hinrichs, D. R., Lillileht, L. U., “A Modified Melting Model for Plastifying Extruders”, Polym. Eng. Sci., 10, 268–278(1970), DOI: 10.1002/pen.760100504Suche in Google Scholar
Hogan, T. A., et al., “The Melting Characteristics of Polycarbonate Resins”, SPE ANTEC Tech. Papers, 384–388(2002)Suche in Google Scholar
Hong, B. K., et al., “Dependence of Melting Behavior on Melt Index”, SPE ANTEC Tech. Papers, 272–276(2001)Suche in Google Scholar
Hughes, T. J. R., et al., “A New Finite Element Formulation for Computational Fluid Dynamics: II. Beyond SUPG”, Comp. Meth. Appl. Mech. Eng., 54, 341–355(1986), DOI: 10.1016/0045-7825(86)90110-6Suche in Google Scholar
Hughes, T. J. R., Mallet, M., “A New Finite Element Formulation for Computational Fluid Dynamics: III. The Generalized Streamline Operator for Multidimensional Advective-Diffusive Systems”, Comp. Meth. Appl. Mech. Eng., 58, 305–328(1986), DOI: 10.1016/0045-7825(86)90152-0Suche in Google Scholar
Hughes, T. J. R., Mallet, M., “A New Finite Element Formulation for Computational Fluid Dynamics: IV. A Discontinuity-Capturing Operator for Multidimensional Advective-Diffusive Systems”, Comp. Meth. Appl. Mech. Eng., 58, 329–336(1986), DOI: 10.1016/0045-7825(86)90153-2Suche in Google Scholar
Hughes, T. J. R., et al., “A New Finite Element Formulation for Computational Fluid Dynamics: VIII. The Galerkin/Least-Squares Method for Advective-Diffusive Equations”, Comp. Meth. Appl. Mech. Eng., 73, 173–189(1989), DOI: 10.1016/0045-7825(89)90111-4Suche in Google Scholar
Kacir, L., Tadmor, Z., “Solids Conveying in Screw Extruders Part III: The Delay Zone”, Polym. Eng. Sci., 12, 387–395(1972), DOI: 10.1002/pen.760120511Suche in Google Scholar
Klenk, P., “Plastifiziermodelle für die Verarbeitung benetzender und nichtbenetzender Thermoplaste auf Einschnecken-Extrudern”, Rheologica Acta, 7, 75–78(1968), DOI: 10.1007/BF01970317Suche in Google Scholar
Kulas, F. R., Thorshaug, N. P., “PVC Powder Extrusion: Melting Properties and Particle Morphology”, J. Appl. Polym. Sci., 23, 1781–1794(1979), DOI: 10.1002/app.1979.070230618Suche in Google Scholar
Lindt, J. T., “A Dynamic Melting Model for a Single-Screw Extruder”, Polym. Eng. Sci., 16, 284–291(1976), DOI: 10.1002/pen.760160411Suche in Google Scholar
Lindt, J. T., “Pressure Development in the Melting Zone of a Single-Screw Extruder”, Polym. Eng. Sci., 21, 1162–1166(1981), DOI: 10.1002/pen.760211708Suche in Google Scholar
Lindt, J. T., Elbirli, B., “Effect of the Cross-Channel Flow on the Melting Performance of a Single-Screw Extruder”, Polym. Eng. Sci., 25, 412–418(1985), DOI: 10.1002/pen.760250706Suche in Google Scholar
Maddock, B., “A Visual Analysis of Flow and Mixing in Extruder Screws”, SPE ANTEC Tech. Papers, 15, 383–389(1959)Suche in Google Scholar
Marshall, D. I., et al., “Measurement of Screw and Plastic Temperature Profiles in Extruders”, SPE J., 20, 329–334(1964)Suche in Google Scholar
Marshall, D. I., Klein, I., “Fundamentals of Plasticating Extrusion. II. Experiments”, Polym. Eng. Sci., 6, 191–197(1966), DOI: 10.1002/pen.760060304Suche in Google Scholar
Martin, G., “Contribution to Determination of Melt Zone Length in Thread of Single-Screw Extruder”, Kunststofftechnik, 7, 238–246(1969)Suche in Google Scholar
Menges, G., Klenk, K. P., “Melting and Plasticating of Unplasticized PVC Powder in the Screw Extruder”, Kunststoffe, 57, 598–603(1967)Suche in Google Scholar
Mennig, G., “Observations Made in the Extrusion of Wall-Slipping Rigid PVC”, Kunststoffe, 71, 359–362(1981)Suche in Google Scholar
Mizukami, A., Hughes, T. J. R., “A Petrov-Galerkin Finite Element Method for Convection-Dominated Flows: An Accurate Upwinding Technique for Satisfying the Maximum Principle”, Comp. Meth. Appl. Mech. Eng., 50, 181–193(1985), DOI: 10.1016/0045-7825(85)90089-1Suche in Google Scholar
Mount, E. M., Chung, C. I., “Melting Behavior of Solid Polymers on a Metal Surface at Processing Conditions”, Polym. Eng. Sci., 18, 711–720(1978), DOI: 10.1002/pen.760180906Suche in Google Scholar
Mount, E. M., et al., “Analytical Melting Model for Extrusion: Melting Rate of Fully Compacted Solid Polymers”, Polym. Eng. Sci., 22, 729–737(1982), DOI: 10.1002/pen.760221202Suche in Google Scholar
Mount, E. M., “Impact of Rheological Properties on Melting Rate Calculations”, SPE ANTEC Tech. Papers, 328–334(2005)Suche in Google Scholar
Pearson, J. R. A., “On the Melting of Solids Near a Hot Moving Interface, with Particular Reference to Beds of Granular Polymers”, Int. J. Heat Mass Transfer, 19, 405–411(1976), DOI: 10.1016/0017-9310(76)90096-XSuche in Google Scholar
Potente, H., “An Analytical Model of Partial and Thorough Melting in Single-Screw Extruders”, Int. Polym. Proc., 6, 297–303(1991)Suche in Google Scholar
Shapiro, J., et al., “Melting in Single Screw Extruders”, Polymer, 17, 905–918(1976), DOI: 10.1016/0032-3861(76)90258-5Suche in Google Scholar
Spalding, M. A., et al., “Three Dimensional Analysis of the Metering Section of a Single Screw Extruder”, SPE-ANTEC Tech. Papers, 1533–1541(1993)Suche in Google Scholar
Stangland, E. E., et al., “Fundamental Characterization of Polypropylene Extrusion”, SPE ANTEC Tech. Papers, 302–306(2002)Suche in Google Scholar
Street, L. F., “Plastifying Extrusion”, Int. Plast. Eng., 1, 289–296(1961)Suche in Google Scholar
Sundstrom, D. W., Young, C. C., “Melting Rates of Crystalline Polymers under Shear Conditions”, Polym. Eng. Sci., 12, 59–63(1972), DOI: 10.1002/pen.760120110Suche in Google Scholar
Sundstrom, D. W., Lo, J. R., “Softening Rates for Polystyrene under Shear Conditions”, Polym. Eng. Sci., 18, 422–426(1978), DOI: 10.1002/pen.760180515Suche in Google Scholar
Syrjala, S., “A New Approach for the Simulation of Melting in Extruders”, Int. Comm. Heat Mass Transfer, 27, 623–634(2000), DOI: 10.1016/S0735-1933(00)00144-5Suche in Google Scholar
Tadmor, Z., “Fundamentals of Plasticating Extrusion. I. A Theoretical Model for Melting”, Polym. Eng. Sci., 6, 185–190(1966), DOI: 10.1002/pen.760060303Suche in Google Scholar
Tadmor, Z., et al., “Melting in Plasticating Extruders – Theory and Experiments”, Polym. Eng. Sci., 7, 198–217(1967), DOI: 10.1002/pen.760070313Suche in Google Scholar
Tadmor, Z., Klien, I., “The Effect of Design and Operating Conditions on Melting in Plasticating Extruders”, Polym. Eng. Sci., 9, 1–10(1969), DOI: 10.1002/pen.760090102Suche in Google Scholar
Tadmor, Z., Gogos, C. G.: Principles of Polymer Processing, John Wiley & Sons, New Jersey(2006)Suche in Google Scholar
Vermeulen, J. R., et al., “The Melting of a Bed of Polymer Granules on a Hot Moving Surface”, Chem. Eng. Sci., 26, 1445–1455(1971a), DOI: 10.1016/0009-2509(71)80064-7Suche in Google Scholar
Vermeulen, J. R., et al., “The Melting of a Crystalline Polymer in a Screw Extruder”, Chem. Eng. Sci., 26, 1457–1465(1971b), DOI: 10.1016/0009-2509(71)80065-9Suche in Google Scholar
Viriyayuthakorn, M., et al., “Three Dimensional Model for Plasticating Extrusion Screw Design”, SPE ANTEC Tech. Papers, 81–84(1984)Suche in Google Scholar
© 2011, Carl Hanser Verlag, Munich
Artikel in diesem Heft
- Contents
- Contents
- Regular Contributed Articles
- Thermal Properties and Electrical Conductivity of Graft Copolymers from Polystyrene and Polyvinyl Propionate with Polyaniline
- Opto-thermo-mechanical Characterization for Polyester and Polyamide Surgical Sutures
- Study on Creep Behavior of PP/CaCO3 Molded by Vibration Injection Molding at Different Vibration Frequency and Vibration Pressure
- Investigation of the Moldability Parameters of PEG Based Steatite Feedstocks by Powder Injection Molding
- Factorial Optimisation of the Effects of Melt Spinning Conditions on Biodegradable As-spun Aliphatic-Aromatic Co-Polyester Fibres
- Erosion Behavior of Glass-epoxy Composites Filled with SiC from Bamboo Leaf
- Modelling Behaviour of PET for Stretch and Micro-Blow Moulding Applications Using an Elasto-Visco-Plastic Material Model
- Melting in a Single Screw Extruder: Experiments and 3D Finite Element Simulations
- Poly(ethylene-co-butylene)-b-(styrene-ran-maleic anhydride)2 Compatibilizers via Nitroxide Mediated Radical Polymerization
- Formation and Biodegradation of Polyethylene-based Electret Films
- Microstructural Evolution of PP/EPDM/Organoclay Nanocomposites in a Twin Screw Extruder
- Effect of Processing Conditions on Properties of PET/Clay Nanocomposite Films
- Rapid Communications
- The Use of Apparent Yield Stress to Characterize Exfoliation in Polymer Nanocomposites
- PPS-News
- PPS News
Artikel in diesem Heft
- Contents
- Contents
- Regular Contributed Articles
- Thermal Properties and Electrical Conductivity of Graft Copolymers from Polystyrene and Polyvinyl Propionate with Polyaniline
- Opto-thermo-mechanical Characterization for Polyester and Polyamide Surgical Sutures
- Study on Creep Behavior of PP/CaCO3 Molded by Vibration Injection Molding at Different Vibration Frequency and Vibration Pressure
- Investigation of the Moldability Parameters of PEG Based Steatite Feedstocks by Powder Injection Molding
- Factorial Optimisation of the Effects of Melt Spinning Conditions on Biodegradable As-spun Aliphatic-Aromatic Co-Polyester Fibres
- Erosion Behavior of Glass-epoxy Composites Filled with SiC from Bamboo Leaf
- Modelling Behaviour of PET for Stretch and Micro-Blow Moulding Applications Using an Elasto-Visco-Plastic Material Model
- Melting in a Single Screw Extruder: Experiments and 3D Finite Element Simulations
- Poly(ethylene-co-butylene)-b-(styrene-ran-maleic anhydride)2 Compatibilizers via Nitroxide Mediated Radical Polymerization
- Formation and Biodegradation of Polyethylene-based Electret Films
- Microstructural Evolution of PP/EPDM/Organoclay Nanocomposites in a Twin Screw Extruder
- Effect of Processing Conditions on Properties of PET/Clay Nanocomposite Films
- Rapid Communications
- The Use of Apparent Yield Stress to Characterize Exfoliation in Polymer Nanocomposites
- PPS-News
- PPS News