The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.
PSE (Polygon Screw Element) is a new screw element, designed to meet the development of co-rotating twin-screw extruders toward high rotating speed and excellent mixing capability. In the present study, a three-dimensional flow field simulation of PSE element was carried out by the ANSYS FEM package. Pressure profile and shear stress profile were obtained. The mixing ability of PSE element was also analyzed. The simulation results of the flow field in PSE element were verified by experiments. It was found that the energy consumed in PSE element is smaller, whereas its mixing ability is better than the kneading block. Furthermore, PSE element is suitable for the fiberglass reinforced processing.
Polyethylene (PE) or polycarbonate (PC) drop breakup process in PE melt under shear flow was investigated using volume-of-fluid method. Real properties of polymers, and temperature and shear rate dependent viscosity model were incorporated in the modeling. An erosion mechanism was found for both PE and PC drops. Local flow information, such as shear rate, viscosity and shear stress, was obtained from the simulation results. Highest shear stress was observed at the interface, which could explain the erosion breakup mechanism.
Foamed products based on renewable raw material have a high application potential e.g. for packaging because of their biodegradeability. This may permit renewable raw materials to substitute polymers like polystyrene in some applications.A common way to process renewable raw material like starch is to produce starch based resins with twin screw extruders. These resins can be used on conventional polymer processing machines, but the step of compounding the starch on twin screw extruders causes costs which make these resins economically unattractive.Due to a new extrusion technology these costs can be reduced by a direct processing of starchy material like maize. A characteristic of this extruder is a very short (2 L/D), conic, multiple flighted screw in a barrel with spiral grooves. The energy for the plasticizing process is yielded just by the transfer of mechanical energy of the rotating screw into friction in a shear gap between screw and barrel.In order to understand the process different geometries of screw and barrel have been used in the experiments, additionally the process parameters have been varied. The results lead to an optimised configuration of the extruder and to a better understanding of the influence of process parameters on the product properties.
The importance of slip for applications such as extrusion, cable coating, thermoforming, etc. has been widely discussed in the literature. Recent experimental works suggested that slipping along the rotors also impacts the quality of the mixing in batch mixers typically used for Carbon Black dispersion. In batch applications, the slip reduces the mixing efficiency, hence requiring a longer process to get a given mixing quality.Recent developments in CFD allow to include the slip in the numerical models. The advantage of numerical simulation is the ability to turn on or off this phenomenon. Also, the effect of particles behavior along the rotors on both the flow pattern and the mixing efficiency of internal mixer is studied. Two 3D transient simulations are performed with the POLYFLOW package: one simulation assumes sticking boundary conditions along the rotors whereas the other involves a full slip condition.The results obtained in both simulations are compared and validated against experimental results: the slip condition modifies dramatically both the velocity and the shear rate fields. Therefore, the distributive and dispersive mixings generated by the two models are significantly different. Eventually, we observe a better match between numerical and experimental results when the slip condition is taken into account.
Nanocomposites based on nylon-12 and synthetic fluoromica were compounded using a single-screw extruder at different combination of shear and residence time and analysed with respect to their morphology, rheological, mechanical, and thermal properties. Transmission electron microscopy (TEM) and X-ray diffraction (XRD) revealed unique structural arrays of the exfoliated layers which were found to be dependent on the extent of shear and residence time during processing. Rheological analysis showed that the melt viscosity of the nanocomposites was considerably lower compared to the unfilled polymer. Furthermore the melt viscosity and properties of each nanocomposite varied depending on orientation of the exfoliated layers. The results show that it may be possible to tailor the structures and properties of the nanocomposites using controlled extrusion conditions.
Extrusion characteristics, such as output, pressure profiles and melting profiles, were investigated in a Brampton Engineering single screw extruder with two screw geometries. It was found that for the wood-HDPE1 composite, the channels were not fully filled until the melting process was completed in both screw geometries. The actual experimental results were compared to those simulated using a commercially available software program. It was found that the current extrusion theories do not predict the pressure profiles generated even for the virgin HDPE1 material for one of the screw geometries.
The focus of this investigation was to evaluate literature and run experiments to help understand the mechanism of melting in single screw extruders. Literature data was re-analyzed using video capture and analysis programs to determine the rate of loss of material in the cross channel and solid bed thickness directions. The analysis demonstrates that the polymer solid bed goes to zero dimension in the thickness direction well before the solid bed width is consumed. This observation was confirmed in our laboratory using a specially built glass barrel extruder. These results suggest that the melting in single screw extruders is dominated by the loss of bed thickness and not bed width as predicted by current literature.
Failure times of plastic and metal pipes subjected to hydrostatic pressure at various levels assist pipe manufacturers to not only design pipes for certain applications, but also to give them an indication of the useful service life-times of these pipes. In order to understand the influence exerted by semicrystalline morphology on the failure of polyethylene pipes under hydrostatic pressure, a medium-density polyethylene resin was converted into various pipes by altering the extrusion processing conditions. These pipes were subsequently subjected to hydrostatic pressure at a constant hoop stress and the failure times were recorded. The failure times were observed to depend strongly on the morphology of the pipes.
When a problem occurs in an extrusion operation it is important to diagnose the problem, determine possible solutions, and implement the best solution in the shortest possible time. In-house personnel are often not well trained in efficient troubleshooting techniques and problem solving. Outside technical assistance may not be immediately available and may not lead to an expedient solution of the problem. As a result, it is important for extrusion companies to have tools available in-house that can help in the troubleshooting and problem solving process.A new tool available to the plastics industry is an expert system that allows computer aided troubleshooting of extrusion problems. This program allows the user to systematically analyze a large number of extrusion problems. In the end the program presents the user with a number of possible solutions to the problem. This paper will describe the capabilities of the program.
The production of filled and reinforced compounds has a high economic importance mainly because fillers and reinforcing fibers render the final product to serve very specific applications. In order to understand such operations more the term “highly filled” will be explained and critical aspects analyzed. In essence two different type of compounding machines are utilized for such compounding tasks, the co-rotating twin-screw and the reciprocating single screw (kneader). Fundamental differences of these systems are analyzed and compared. Examples of compounding processes are described.
A study has been performed to examine the rheological impact of micropelletization on several polyethylene grades with melt index values between 1-5 g/10 min. The experiments were done on a 50 mm 30:1 L/D extruder with an underwater micropelletizer attached. A 2-D finite element simulation was used to assist in the analysis by comparing the observed results to the predicted shear stresses in the die. The average micropellet size collected was 0.525 mm diameter. Minor sharkskin was observed on the surface of micropellets due to the high stresses experienced in the pelletizer die. However, the rheological properties of the micropellets did not change in comparison to the virgin resins.
Interest in nanocomposites is based on the premise that with a relatively small loading of properly dispersed treated clay, polymers can exhibit substantial improvement in properties. These include thermal properties such as HDT, mechanical properties such as flexural strength and modulus (without significant loss of impact), barrier properties, flame resistance, and abrasion resistance. While the concept behind nanocomposites is sound, implementation has been flawed. Dispersion of 8 micron clay particles into a million or so high aspect ratio platelets is a difficult task. Both chemical modification of the clay for improved compatibility, and development of specific compounding technology have shown promise but not been fully successful. In previous work (1) unit operations that have significant impact on clay dispersion in the co-rotation twin-screw extruder were identified. This presentation will review the design flexibility associated with the reciprocating single screw, or kneader, compounding system and discuss key unit operations necessary to obtain well dispersed clay. It will also compare results from the reciprocating single screw system with those obtained from previous work on a twin-screw extruder.
The work presents both, simulation and experimental findings of the research of two LDPE melts using a flat coextrusion flow visualization cell. The simulation is performed by FEM analysis with full u-v-p-? numerical scheme employing viscoelastic constitutive equations. The predicted stresses, velocities and interface location have been found to be in a good agreement with the measurements. The experimental analysis shows that pronounced wave instabilities are caused by the minor layer break at the merge point of the layers, and extensional viscosity is a driving parameter here. Finally, recently proposed ‘TNSD sign criterion‘ has been successfully tested for the prediction of the onset of wave interfacial instabilities in this type of the die geometry.
The study of two low density polyethylene melt flows in slit coextrusion flow cells with 30° and 90° confluent geometries is presented. The stream flows and polymerpolymer interface in the confluent region and die land are observed through side windows of the cell. Birefringence and image processing techniques are used to quantify stress and velocity fields in the upstream and down stream melt flows. Interfacial instabilities were observed in the LDPE melt flows in both geometries. Instabilities occurred at certain stream mass flow ratios. Digital image processing shows the wave type extrudate instabilities have the same periodicity as perturbation in the flow field in the die land. A recently proposed “TNSD sign criterion” reasonably predicted the onset of the interfacial instabilities in these die geometries.
The design of an optimal spiral mandrel die suited to given requirements is quite a complicated task for the die designer. Even for a properly designed spiral section, there is always a question how variations in the flow prior to the spiral channels can influence the melt distribution at the exit of the spiral distribution section. This study uses 3D FEM analysis to investigate an effect of having uneven inputs. Specifically, the influence of uneven mass and temperature input distributions are studied. The influence of the die distributive system is investigated by analyzing the temperature and velocity fields at the exit.
Fluctuations of the operating conditions or slight variations of the polymer rheology may occur during longterm productions, affecting the performance of the die in an extent dependent on its flow distribution sensitivity. In this work, four extrusion dies are optimised (balanced) using different design methodologies. These are compared in terms of their performance and stability to some operating conditions and polymer rheological properties. A finite-volume based computational code is used to perform the required simulations of the non-isothermal three-dimensional flows, under conditions defined by a statistical Taguchi technique. Correlation between the flow patterns developed and flow distribution sensitivity is also investigated.
Flow of a polymer in an intermeshing co-rotating twin-screw extruder is simulated. Effect of elongational viscosity on the flow is analyzed using independent power-law models for the shear and elongational viscosities. Axial component of the velocity is found to be maximum in the intermeshing region of the extruder. Axial component of velocity, which determines the throughput of the extruder, decreased as the elongational viscosity of the polymer used for the flow simulation was increased. The pressure in the extruder decreased from a very high positive value on the leading edge to a very large negative value on the trailing edge of the screw. For the same rotational speed the pressure build-up in the twin-screw extruder increased as the elongational viscosity of the polymer was increased.
It has been demonstrated experimentally, that Plastic Energy Dissipation (PED) is the most important heating/melting mechanism, especially in the initial stage of heating of compacted solid polymer particulates in polymer compounding equipment, where forced particulate deformation takes place. Our previous work has also found that the melting of multi-component polymer blends is totally different from that of the individual blend component. The difference has been correlated to the different PED response of individual blend components in the deformation of polymer blends. In this work, we study the PED behavior of model polymer blends (PE/PS) at different compositions as well as the effect of a compatibilizer on the blend PED. The Specific Mechanical Energy (SME) input associated with PED of both uncompatibilized polymer blends and compatibilized polymer blends during uniaxial compressive deformation is calculated and compared.
Co-rotating twin-screw extruders are frequently used in the field of polymer compounding processes. The extruders are build in a modular design with different conveying and mixing elements to be adapted of specific processes. The user operating the machines often has an optimization problem: On the one hand a gentle mechanical treatment during the flow through the extruder are required. Otherwise there is the desire for a flow rate as much as possible. Therefore Coperion Werner & Pfleiderer has developed a new model series with deeper screw flights, because the ratio of outer versus root diameter is one of the characteristic dimensions of a screw extruder.To estimate and evaluate the success of the new model series, numerical simulations have been carried out of the three dimensional fluid flow in such twin-screw extruders. The approximation based on a finite volume method with contour-adapted meshes. The calculations are made in a relative system, where the flow appears in a steady state.In this paper we present results of numerical investigations of single- and double-flighted screw elements and compare these with calculated values of an old model range with smaller diameter ratio. We discuss not only the conveying- and power-characteristics for Newtonian and nonnewtonian highly viscous materials but also the distribution of shear rate and shear stress. It is shown that the deeper screw flights are a good choice to take care of the polymer material and reduce the energy consumption of many processes.
Tightly Intermeshing, co-rotating twin screw extruders are commonly employed for tasks requiring good mixing. The modular constitution of both barrel and screw makes it possible to optimize the extruder configuration for a given task. This research focuses on the optimization of individual screw elements, thus the development of an optimized geometry for different materials and operating conditions.We calculated the pressure profile, the temperature development and the power consumption using one-dimensional models. A non-linear optimization algorithm was used to vary the geometrical data of the screw elements of interest. The goal was to find a geometry that shows an optimum between the contradicting goals of a minimum temperature increase, a minimum power consumption and a capability to build up a certain pressure with in a minimum distance (i.e. maximum pressure gradient). The quality of the geometry was characterized and evaluated by quality functions. We verified the optimization method by systematic experimental investigations.
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ANTEC 2016 - Indianapolis, Indiana, USA May 23-25, 2016. [On-line].
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