Home Numerical Investigation of Effect of Rotor Phase Angle in Partially-Filled Rubber Mixing
Article
Licensed
Unlicensed Requires Authentication

Numerical Investigation of Effect of Rotor Phase Angle in Partially-Filled Rubber Mixing

  • S. R. Das , H. Poudyal and A. J. Chandy
Published/Copyright: June 13, 2017
Become an author with De Gruyter Brill

Abstract

Among several operational parameters such as rotor speed, fill factor and ram pressure, the orientation of the mixing rotors with respect to each other plays a significant role in the mixing performance. An understanding of the flow field and mixing characteristics associated with the orientations of the rotors will help in obtaining a final product with a better quality. For that purpose three phase angle orientations: 45°, 90° and 180° are investigated here in a 75% filled chamber with two rotors counter-rotating at an even speed of 20 min–1. Two dimensional, transient, isothermal, incompressible simulations are carried out using a CFD code. While an Eulerian multiphase method was used to solve for the transport variables in the two phases: rubber and air, the volume of fluid (VOF) method was used to solve for the interface between the two phases. A non-Newtonian Carreau-Yasuda model was used to characterize rubber. Massless particles were injected in the domain to calculate statistical quantities in order to assess dispersive and distributive mixing characteristics associated with rotor orientations. The flow field is analyzed via pressure and velocity contours. Dispersive mixing was analyzed through histograms of mixing index and cumulative probability distribution functions of maximum shear stress experienced by the particles. Distributive mixing was quantified statistically using cluster distribution index and interchamber material transfer. The phase angle of 180° was found to perform the best in terms of both dispersive and distributive mixing characteristics.


*Correspondence address, Mail address: Abhilash J. Chandy, ASEC 101, Department of Mechanical Engineering, University of Akron, Akron, Ohio, 44325-3903, USA, E-mail:

References

Alsteens, B., Avalosse, T., Legat, V., Marchal, T. and Slachmuylders, E., “Effect of the Full-Slip Condition along Rotors on the Mixing Efficiency of Internal Mixers”, Society of Plastics Engineers Annual Technical Conference, ANTEC, Nashville, TN, USA, 173177 (2003)Search in Google Scholar

Avalosse, T., Alsteens, B. and Legat, V., “Rotor Shape Design by Numerical Simulation: A New Way to Improve Dispersive and Distributive Mixing in Batch Mixer”, Elastomery, 9, 1624 (2005)Search in Google Scholar

Cheng, H., Manas-Zloczower, I., “Distributive Mixing in Conveying Elements of a ZSK-53 Co-Rotating Twin Screw Extruder”, Polym. Eng. Sci., 38, 926935 (1998) 10.1002/pen.10260Search in Google Scholar

Cheng, J., Manas-Zloczower, I., “Flow Field Characterization in a Banbury Mixer”, Int. Polym. Proc., 5, 178183 (1990) 10.3139/217.900178Search in Google Scholar

Cheng, J.-J., Manas-Zloczower, I., “Hydrodynamic Analysis of a Banbury Mixer 2D Flow Simulations for the Entire Mixing Chamber”, Polym. Eng. Sci., 29, 10591065 (1989) 10.1002/pen.760291102Search in Google Scholar

Collin, V., Peuvrel-Disdier, E., Alsteens, B., Legat, V., Avalosse, T., Otto, S. and Metwally, H.M., “Numerical and Experimental Study of Dispersive Mixing of Agglomerates”, Society of Plastics Engineers Annual Technical Conference, ANTEC, Charlotte, NC, USA, 908912 (2006)Search in Google Scholar

Connelly, R.K., Kokini, J.L., “The Effect of Shear Thinning and Differential Viscoelasticity on Mixing in a Model 2D Mixer as Determined Using FEM with Particle Tracking”, J. Non Newtonian Fluid Mech., 123, 117 (2004) 10.1016/j.jnnfm.2004.03.006Search in Google Scholar

Connelly, R.K., Kokini, J.L., “Examination of the Mixing Ability of Single and Twin Screw Mixers using 2D Finite Element Method Simulation with Particle Tracking”, J. Food Eng., 79, 956969 (2007) 10.1016/j.jfoodeng.2006.03.017Search in Google Scholar

Dhanasekharan, K.M., Kokini, J.L., “Design and Scaling of Wheat Dough Extrusion by Numerical Simulation of Flow and Heat Transfer”, J. Food Eng., 60, 421430 (2003) 10.1016/S0260-8774(03)00065-7Search in Google Scholar

Emin, M., Schuchmann, H., “Analysis of the Dispersive Mixing Efficiency in a Twin-Screw Extrusion Processing of Starch Based Matrix”, J. Food Eng., 79, 956969 (2012)Search in Google Scholar

Fukutani, K., Higashi, K., Yamada, S. and Yamane, Y., “Numerical Study on Distributive Mixing Characteristics in a Partially Filled Internal Mixer”, American Chemical Society Division of Rubber Chemistry, 1, 914925 (2013)Search in Google Scholar

Keuter, H., Rinker, M., “Rotor Optimization to Improve Mixing Efficiency”, European Rubber Research – Practical Improvements of the Mixing Process: SATPRO, ROTOR and Dust Stop, International Conference, Paderborn, Germany, 271294 (2005)Search in Google Scholar

Kim, J.K., White, J.L., “An Experimental and Theoretical Study of Starvation Effects on Flow and Mixing Elastomers in an Internal Mixer”, Nihon Reoroji Gakkaishi (Journal of the Society of Rheology, Japan), 17, 203210 (1989)10.1678/rheology1973.17.4_203Search in Google Scholar

Leblanc, J.L., Lionnet, R., “Determining the Components of Mixing Energy when Preparing Rubber Compounds in Instrumented Internal Mixers”, Polym. Eng. Sci., 32, 989997 (1992) 10.1002/pen.760321503Search in Google Scholar

Limper, A., Hesse, M., “Investigation of Rotor Blades and the Geometrical Effects on the Flow Behavior in Internal Mixer”, European Rubber Research – Practical Improvements of the Mixing Process: SATPRO, ROTOR and Dust Stop, International Conference, Paderborn, Germany, 208218 (2005)Search in Google Scholar

Limper, A., Kelting, K.U., “Mixing of Silica Compounds: Higher Silanization Efficiency by Adapted Process and Machine Design”, European Rubber Research – Practical Improvements of the Mixing Process: SATPRO, ROTOR and Dust Stop, International Conference, Paderborn, Germany, 1644 (2005)Search in Google Scholar

Liu, J., Li, F., Zhang, L. and Yang, H., “Numerical Simulation of Flow of Rubber Compounds in Partially Filled Internal Mixer”, J. Appl. Polym. Sci., 132, 42496 (2015) 10.1002/app.42496Search in Google Scholar

Manas-Zloczower, I., “Analysis of Mixing in Polymer Processing Equipment”, Rheol. Bull., 66, 58 (1997)Search in Google Scholar

Manas-Zloczower, I.: Mixing and Compounding of Polymers: Theory and Practice, Hanser Publishers, Munich (2012)Search in Google Scholar

Muzaferija, S., Peric, M., Sames, P. and Schellin, T., “A Two-Fluid Navier-Stokes Solver to Simulate Water Entry”, in 22nd Symposium on Naval Hydrodynamics, Naval Hydrodynamics, National Academy Press, 638651 (1999)Search in Google Scholar

Nassehi, V., Ghoreishy, M., “Modeling of Mixing in Internal Mixers with Long Blade Tips”, Adv. Polym. Technol., 20, 132145 (2001) 10.1002/adv.1011Search in Google Scholar

Nortey, N. O., US Patent 4 714 350 (1987)Search in Google Scholar

Nortey, N. O., US Patent 4 834 543 (1989)Search in Google Scholar

Rathod, M.L., Kokini, J.L., “Effect of Mixer Geometry and Operating Conditions on Mixing Efficiency of a Non-Newtonian Fluid in a Twin Screw Mixer”, J. Food Eng., 118, 256265 (2013) 10.1016/j.jfoodeng.2013.04.020Search in Google Scholar

Salahudeen, S.A., Elleithy, R.H., AlOthman, O. and AlZahrani, S., “Comparative Study of Internal Batch Mixer Such as Cam, Banbury and Roller: Numerical Simulation and Experimental Verification”, Chem. Eng. Sci., 66, 25022511 (2011) 10.1016/j.ces.2011.02.017Search in Google Scholar

Schuster, R.H., “Dispersion of Fillers – a Decisive Factor for the Processing of Rubber Compounds and the Performance of Elastomers”, European Rubber Research – Practical Improvements of the Mixing Process: SATPRO, ROTOR and Dust Stop, International Conference, Paderborn, Germany, 185206 (2005)Search in Google Scholar

Toh, M., Gondoh, T., Mori, T. and Mishima, M., “Mixing Characteristics of an Internal Mixer: Uniformity of Mixed Rubber”, J. Appl. Polym. Sci., 95, 166172 (2005) 10.1002/app.20816Search in Google Scholar

Vyakaranam, K., Evans, M., Ashokan, B. and Kokini, J.L., “Evaluation of Mixing and Air Bubble Dispersion in Viscous Liquids Using Numerical Simulations”, in Food Mixing, Cullen, P. J. (Ed.), Blackwell Publishing, Oxford, UK (2009) 10.1002/9781444312928.ch12Search in Google Scholar

Vyakaranam, K.V., Ashokan, B.K. and Kokini, J.L., “Evaluation of Effect of Paddle Element Stagger Angle on the Local Velocity Profiles in a Twin-Screw Continuous Mixer with Viscous Flow Using Finite Element Method Simulations”, J. Food Eng., 108, 585599 (2012) 10.1016/j.jfoodeng.2010.12.001Search in Google Scholar

Vyakaranam, K.V., Kokini, J.L., “Prediction of Air Bubble Dispersion in a Viscous Fluid in a Twin Screw Continuous Mixer Using FEM Simulations of Dispersive Mixing”, Chem. Eng. Sci., 84, 303314 (2012) 10.1016/j.ces.2012.07.014Search in Google Scholar

Wang, W., Manas-Zloczower, I., “Temporal Distributions: The Basis for the Development of Mixing Indexes for Scale-Up of Polymer Processing Equipment”, Polym. Eng. Sci., 41, 10681077 (2001) 10.1002/pen.10807Search in Google Scholar

Wong, T.H., Manas-Zloczower, I., “Two-Dimensional Dynamic Study of the Distributive Mixing in an Internal Mixer”, Int. Polym. Proc., 9, 310 (1994) 10.3139/217.940003Search in Google Scholar

Wu, S., “Calculation of Interfacial Tension in Polymer Systems”, J. Polym. Sci. Polym. Symp., 34, 1930 (1971) 10.1002/polc.5070340105Search in Google Scholar

Yang, H.-H., Manas-Zloczower, I., “Analysis of Mixing Performance in a Vic Mixer”, Int. Polym. Proc., 9, 291302 (1994) 10.3139/217.940291Search in Google Scholar

Received: 2016-08-09
Accepted: 2016-12-22
Published Online: 2017-06-13
Published in Print: 2017-07-30

© 2017, Carl Hanser Verlag, Munich

Articles in the same Issue

  1. Contents
  2. Contents
  3. Review Articles
  4. Influence of Carbon Fillers on Thermal Properties and Flammability of Polymeric Nanocomposites
  5. Regular Contributed Articles
  6. Polymer Flow Behavior Analysis Based on Physical Visualization Technology for Ultrasonic Vibration-Assisted Injection Molding
  7. Flexural Fatigue Performance of Glass Fiber/Epoxy Step-Wise Functionally and Non-Functionally Graded Composites of Different Structures
  8. Establishment and Effect of Constraint on Different Mechanical Properties of Bamboo Filler Reinforced Epoxy Composite
  9. Experimental Investigation on Mechanical and Thermo-Mechanical Properties of Alumina Filled Polypropylene Composites Using Injection Molding Process
  10. Development and Characterization of Polyurethane and Acrylonitrile Butadiene Styrene and their Compatibilized Blends
  11. Mechanical Properties of Polydimethylsiloxane as a Function of the Amount and Type of Crosslinking Agent
  12. Numerical Investigation of Effect of Rotor Phase Angle in Partially-Filled Rubber Mixing
  13. Method of Calculating the Fluid Permeability of Machined Skin-Covered Porous Sheets from Experimental Flow Data
  14. Analysis of Models Predicting Morphology Transitions in Reactive Twin-Screw Extrusion of Bio-Based Polyester/Polyamide Blends
  15. A Combined Experimental and Modelling Approach towards an Optimized Heating Strategy in Thermoforming of Thermoplastics Sheets
  16. Analyzing the Influence of Surface Renewal on Diffusive Mass Transport in Vented Single-Screw Extruders
  17. Research on Optimizing Parameters of Thermal Bonding Technique for PMMA Microfluidic Chip
  18. PPS News
  19. PPS News
  20. Seikei Kakou Abstracts
  21. Seikei-Kakou Abstracts
Downloaded on 27.10.2025 from https://www.degruyterbrill.com/document/doi/10.3139/217.3346/html
Scroll to top button