MODELLING OF COUNTER ROTATING TWIN SCREW EXTRUSION

Abstract

<p>Intermeshing counter-rotating twin screw extruders (ICRTSE) are used extensively in the polymer processing industry for pelletizing, devolatilization and extrusion of various plastic products. ICRTSE have better positive displacement ability and are more suitable for shear sensitive materials compared to other types of twin screw extruders.</p> <p>The objectives of this thesis are to understand the flow mechanism and the effects of screw geometries and processing conditions in the ICRTSE. First, a simple flow model based on a volume of the conveying element of ICRTSE was used to calculate flow rate. Since ICRTSE do not give complete positive displacement, the various leakage flows were identified and taken into account in the simple flow model. Although the simple flow model provided reasonable results in terms of flow rate, computer simulations were found necessary due to the limitations of simple flow model. Second, a 3D computer simulation of ICRTSE was developed for various screw geometries and processing conditions. Both Newtonian and non-Newtonian fluids were examined.</p> <p>It was shown the simple model based on geometrical parameters for pumping behaviour give reasonable prediction of flow rate. It was found that determination of negative pressure should be taken into account in numerical simulations. The pumping efficiency is influenced positively by the ratio of flight width-to-channel width but it is affected negatively by the screw pitch length. It is negligibly changed with screw speed. Finally, the dominant flow is shear flow in ICRTSE and therefore, dispersive mixing capacity is very limited due to a lack of elongational effects.</p>