Modeling of melting process in a single screw extruder for polymer processing
Keywords:single-screw extruder, polymer, granule, melting zone, boundary conditions, polymer stopper, temperature field
We developed a mathematical model of the melting zone of a single-screw extruder for processing of polymers. The model takes into account a heat transfer of a polymer with a worm and a cylinder of an extruder (parameters of a heat transfer agent in the worm, as well as parameters of a heat carrier or electric heaters on the outer surface of the cylinder), as well as the real boundary conditions (the worm rotates, the cylinder is fixed).
The classical and most commonly spread plane-parallel model of the melting process, in contrast to the developed model, considers a fixed worm and a rotating cylinder extended on the plane. Therefore, processes that actually occur near the surface of a rotating worm are conditionally transferred to the side of a fixed cylinder and vice versa. It distorts fields of speed and temperature of a polymer in the worm channel, as well as the viscosity value of a polymer along the channel height.
We investigated a temperature field of a polymer in the worm channel, as well as a relative width of a polymeric stopper along the length of the melting zone of the extruder (the ratio of a width of the polymer stopper to a width of the worm channel). We compared results of the calculation with the experiment. We showed that the proposed model describes the process of melting of a polymer better than the classical inverse plane-parallel model. We also proposed the approach to modeling of an extruder in general as sequences of its interconnected functional zones.
The difference between calculated and measured values of the dimensionless width of the polymeric "stopper" from the dimensionless coordinate along the axis of the worm does not exceed 15 %. This is less than at using the traditional approach to modeling of the melting process.
The developed technique was successfully implemented for the modes of processing of various polymeric materials at extruders with worms of diameter 32, 45, 63, 90, and 125 mm.The use of the developed mathematical model will make it possible to better forecast effective modes of the worm extruder, especially if it is necessary to account for heat transfer between surfaces of a worm and a cylinder, as well as processing of materials characterized by low thermal resistance
- Mirovoy i evropeyskiy rynok plastmass (2005). Plastics Review (Ukraine Edition), 4–8.
- Rauwendaal, C. (2014). Polymer extrusion. Munich: Carl Hanser Verlag, 950. doi: 10.3139/9781569905395
- Mikulionok, I. O. (2015). Classification of Processes and Equipment for Manufacture of Continuous Products from Thermoplastic Materials. Chemical and Petroleum Engineering, 51 (1-2), 14–19. doi: 10.1007/s10556-015-9990-6
- Schenkel, G. (1959). Schneckenpressen für kunststoffe. München: Carl Hanser Verlag, 467.
- Tadmor, Z., Gogos, C. G. (2006). Principles of polymer processing. New Jersey: John Wiley & Sons, Inc., 962.
- Mikulyonok, I. O. (2013). Equipment for preparing and continuous molding of thermoplastic composites. Chemical and Petroleum Engineering, 48 (11-12), 658–661. doi: 10.1007/s10556-013-9676-x
- Mikulionok, I. O. (2013). Screw extruder mixing and dispersing units. Chemical and Petroleum Engineering, 49 (1-2), 103–109. doi: 10.1007/s10556-013-9711-y
- Weltrekord bei PE-Aufbereitung (2000). Kunststoffe, 90 (3), 12.
- Donovan, R. C. (1971). A theoretical melting model for plasticating extruders. Polymer Engineering and Science, 11 (3), 247–257. doi: 10.1002/pen.760110313
- Edmondson, I. R., Fenner, R. T. (1975). Melting of thermoplastics in single screw extruders. Polymer, 16 (1), 49–56. doi: 10.1016/0032-3861(75)90095-6
- Shapiro, J., Halmos, A. L., Pearson, J. R. A. (1976). Melting in single screw extruders. Polymer, 17 (10), 905–918. doi: 10.1016/0032-3861(76)90258-5
- Lee, K. Y., Han, C. D. (1990). Analysis of the performance of plasticating single-screw extruders with a new concept of solid-bed deformation. Polymer Engineering and Science, 30 (11), 665–676. doi: 10.1002/pen.760301106
- Syrjälä, S. (2000). A new approach for the simulation of melting in extruders. International Communications in Heat and Mass Transfer, 27 (5), 623–634. doi: 10.1016/s0735-1933(00)00144-5
- Wilczyński, K., Nastaj, A., Wilczyński, K. J. (2013). Melting Model for Starve Fed Single Screw Extrusion of Thermoplastics. International Polymer Processing, 28 (1), 34–42. doi: 10.3139/217.2640
- Alfaro, J. A. A., Grünschloß, E., Epple, S., Bonten, C. (2015). Analysis of a Single Screw Extruder with a Grooved Plasticating Barrel – Part I: The Melting Model. International Polymer Processing, 30 (2), 284–296. doi: 10.3139/217.3021
- Gaspar-Cunha, A., Covas, J. A. (2013). The plasticating sequence in barrier extrusion screws part I: Modeling. Polymer Engineering & Science, 54 (8), 1791–1803. doi: 10.1002/pen.23722
- Gaspar-Cunha, A., Covas, J. A. (2014). The Plasticating Sequence in Barrier Extrusion Screws Part II: Experimental Assessment. Polymer-Plastics Technology and Engineering, 53 (14), 1456–1466. doi: 10.1080/03602559.2014.909482
- Wilczyński, K. J., Lewandowski, A., Wilczyński, K. (2016). Experimental study of melting of polymer blends in a starve fed single screw extruder. Polymer Engineering & Science, 56 (12), 1349–1356. doi: 10.1002/pen.24368
- Mikulonok, I. O. (2009). Obladnannia i protsesy pererobky termoplastychnykh materialiv z vykorystanniam vtorynnoi syrovyny. Kyiv: IVTs „Vydavnytstvo «Politekhnika»”, 265.
- Mikulionok, I. O., Radchenko, L. B. (2012). Screw extrusion of thermoplastics: I. General model of the screw extrusion. Russian Journal of Applied Chemistry, 85 (3), 489–504. doi: 10.1134/s1070427211030305
- Mikulionok, I. O., Radchenko, L. B. (2012). Screw extrusion of thermoplastics: II. Simulation of feeding zone of the single screw extruder. Russian Journal of Applied Chemistry, 85 (3), 505–514. doi: 10.1134/s1070427211030317
- Mikulenok, I. O. (2012). Determining the thermophysical properties of thermoplastic composite materials. Plasticheskie Massy, 5, 23–28. Available at: http://www.polymerjournals.com/pdfdownload/1144538.pdf
How to Cite
Copyright (c) 2018 Ihor Mikulionok, Oleksandr Gavva, Liudmyla Kryvoplias-Volodina
This work is licensed under a Creative Commons Attribution 4.0 International License.
The consolidation and conditions for the transfer of copyright (identification of authorship) is carried out in the License Agreement. In particular, the authors reserve the right to the authorship of their manuscript and transfer the first publication of this work to the journal under the terms of the Creative Commons CC BY license. At the same time, they have the right to conclude on their own additional agreements concerning the non-exclusive distribution of the work in the form in which it was published by this journal, but provided that the link to the first publication of the article in this journal is preserved.
A license agreement is a document in which the author warrants that he/she owns all copyright for the work (manuscript, article, etc.).
The authors, signing the License Agreement with PC TECHNOLOGY CENTER, have all rights to the further use of their work, provided that they link to our edition in which the work was published.
According to the terms of the License Agreement, the Publisher PC TECHNOLOGY CENTER does not take away your copyrights and receives permission from the authors to use and dissemination of the publication through the world's scientific resources (own electronic resources, scientometric databases, repositories, libraries, etc.).
In the absence of a signed License Agreement or in the absence of this agreement of identifiers allowing to identify the identity of the author, the editors have no right to work with the manuscript.
It is important to remember that there is another type of agreement between authors and publishers – when copyright is transferred from the authors to the publisher. In this case, the authors lose ownership of their work and may not use it in any way.