pps proceeding - Abstract Preview
pps proceeding
Symposium: G10 - Modeling and simulation
Oral Presentation
 
 

Numerical Simulation of Residence Time, Shear Rates and Throughput in Single Screw Extruders Considering Wall Shear Rates

Wittke Marius (1)*, Prof. Dr.-Ing. Moritzer Elmar (1), Heiderich Gilmar (1)

(1) Kunststofftechnik Paderborn - Nordrhein-Westfalen - Germany

In this paper, a model for the dimensionless pressure-throughput relation for non-newtonian fluids according to POTENTE is augmented by considering wall shear stresses. Therefore, computational fluid simulations (CFD) of single screw extruders are conducted to identify the dimensionless throughput. The throughput is calculated based upon a given pressure resulting from the model according to POTENTE. It can be shown, that the existing model can be augmented considering wall shear stresses using an exponential expression. This expression is a function of pressure, viscosity and geometry of the single screw. A dimensionless design of experiments leads to results that enable the new model to predict the throughput for various geometries, materials and operating points. The simulation results are verified using the simulation program REX by Kunststofftechnik Paderborn, which is widely used in the market and well verified by industrial appliers. It can be shown that the the average deviation between CFD simulation results and REX is less than 10%. Furthermore, an investigation concerning shear stresses along the channel width and height is conducted in order to build up a second model. This model predicts shear stresses among the same variety of geometries, materials and operating points. Predicting shear stresses as an indicator of material stress inside the channel can be used to simulate mixing or damaging processes of additives like fibers. Finally, the CFD simulations are amplified using particle tracking. Mass less particles are injected inside the single screw and their residence time is being monitored. Thereby, the described model is augmented by a third equation that predicts residence times as a function of the above mentioned parameters. Resuming, a model is created and verified that predicts throughput, shear stresses and residence times for a wide range of geometries, materials and operating points based upon three-dimensional CFD simulations.