Modeling of melting process in a single screw extruder for polymer processing

Authors

  • Ihor Mikulionok National Technical University of Ukraine "Igor Sikorsky Kyiv Polytechnic Institute" Peremohy ave., 37, Kyiv, Ukraine, 03056, Ukraine https://orcid.org/0000-0001-8268-7229
  • Oleksandr Gavva Educational-Scientific Engineering-Technical Institute named after acad. I. S. Gulogo National University of Food Technologies Volodymyrska str., 68, Kyiv, Ukraine, 01601, Ukraine https://orcid.org/0000-0003-2938-0230
  • Liudmyla Kryvoplias-Volodina EdEducational-Scientific Engineering-Technical Institute named after acad. I. S. Gulogo National University of Food Technologies Volodymyrska str., 68, Kyiv, Ukraine, 01601, Ukraine https://orcid.org/0000-0001-9906-6381

DOI:

https://doi.org/10.15587/1729-4061.2018.127583

Keywords:

single-screw extruder, polymer, granule, melting zone, boundary conditions, polymer stopper, temperature field

Abstract

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

Author Biographies

Ihor Mikulionok, National Technical University of Ukraine "Igor Sikorsky Kyiv Polytechnic Institute" Peremohy ave., 37, Kyiv, Ukraine, 03056

Doctor of Technical Sciences, Professor

Department of chemical, polymeric and silicate mechanical engineering

Oleksandr Gavva, Educational-Scientific Engineering-Technical Institute named after acad. I. S. Gulogo National University of Food Technologies Volodymyrska str., 68, Kyiv, Ukraine, 01601

Doctor of Technical Sciences, Professor

Department of machines and apparatus for food and pharmaceutical productions

Liudmyla Kryvoplias-Volodina, EdEducational-Scientific Engineering-Technical Institute named after acad. I. S. Gulogo National University of Food Technologies Volodymyrska str., 68, Kyiv, Ukraine, 01601

PhD, Associate Professor

Department of Mechatronics and Packaging Technology

References

  1. Mirovoy i evropeyskiy rynok plastmass (2005). Plastics Review (Ukraine Edition), 4–8.
  2. Rauwendaal, C. (2014). Polymer extrusion. Munich: Carl Hanser Verlag, 950. doi: 10.3139/9781569905395
  3. 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
  4. Schenkel, G. (1959). Schneckenpressen für kunststoffe. München: Carl Hanser Verlag, 467.
  5. Tadmor, Z., Gogos, C. G. (2006). Principles of polymer processing. New Jersey: John Wiley & Sons, Inc., 962.
  6. 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
  7. 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
  8. Weltrekord bei PE-Aufbereitung (2000). Kunststoffe, 90 (3), 12.
  9. Donovan, R. C. (1971). A theoretical melting model for plasticating extruders. Polymer Engineering and Science, 11 (3), 247–257. doi: 10.1002/pen.760110313
  10. 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
  11. 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
  12. 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
  13. 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
  14. 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
  15. 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
  16. 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
  17. 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
  18. 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
  19. Mikulonok, I. O. (2009). Obladnannia i protsesy pererobky termoplastychnykh materialiv z vykorystanniam vtorynnoi syrovyny. Kyiv: IVTs „Vydavnytstvo «Politekhnika»”, 265.
  20. 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
  21. 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
  22. 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

Downloads

Published

2018-04-03

How to Cite

Mikulionok, I., Gavva, O., & Kryvoplias-Volodina, L. (2018). Modeling of melting process in a single screw extruder for polymer processing. Eastern-European Journal of Enterprise Technologies, 2(5 (92), 4–11. https://doi.org/10.15587/1729-4061.2018.127583

Issue

Section

Applied physics