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Fill ratio distribution in a co-rotating self-wiping
twin screw extruder—theoretical and
experimental studyKentaro Taki, Kanazawa University, Kanazawa, Ishikawa, Japan,
Shin-ichiro Tanifuji, HASL, Tokyo, Japan,
Takemasa Sugiyama, Kanazawa University, Kanazawa, Ishikawa, Japan
Jun-ichi Murata, Kaneka, Osaka, Japan,
Isao Tsujimura, Kaneka, Osaka, Japan
8:00-8:30am 30 min.
(C)Kentaro Taki, Kanazawa University1
Agenda
1. Introduction
2. Theory and formulation
3. Algorithm for fill ratio distribution
4. Conclusion
(C)Kentaro Taki, Kanazawa University2
Numerical Simulation of TSE
Calculation time
Re
solu
tio
n
3D sim etc
FAN method
This study
[1]
[3]
[2]
1 s 1-10 min 1 day-1 week
1. Yasuya Nakayama, Toshihisa Kajiwara, Tatsunori Masaki, AIChE J, 62(7), 2563-2569 (2016).b
2. Andreas Eitzlmayr, Johannes Khinast, Chemical Engineering Science, 134, 861-879 (2015).
3. Tadmor, Z., Broyer, E. and Gutfinger, C.: Polym. Eng. Sci., 14,660(1984)
4. Broyer, E., Gutfinger, C. and Tadmor Z. : Trans. Soc. Rheology, 19, 423(1975)
5. J. L. White, Z. Y. Chen, Polymer Engineering and Science, 34(3), 229-237 (1994).
6. Santosh Bawiskar, James L. White, Polymer Engineering & Science, 38(5), 727-740 (1998).
7. James L. White, Eung Kyu Kim, Jong Min Keum, Ho Chul Jung, Dae Suk Bang, Polymer Engineering & Science, 41(8), 1448-1455 (2001).
8. J. L. White, B. J. Kim, S. Bawiskar, J. M. Keum, Polymer-Plastics Technology and Engineering, 40(4), 385-405 (2001).(C)Kentaro Taki, Kanazawa University
3
What our simulator can do.
Hele-Shaw flow model + finite element method
Fill ratio distribution
Pressure distribution
Strain magnitude Droplet dispersion Fiber attrition Plasticization
Strain rate, velocity, flow rate distribution on whole screw elements
(C)Kentaro Taki, Kanazawa University4
Advantage of our software
5
Q1Q2
Q3Q4
1. Calculation cost is low as the pressure is the only unknown variable to
be determined for isothermal condition.
2. It is easy to calculate flow metrics; velocity, strain rate, viscosity
distribution by the integration along the thickness (r direction) when
the pressure and temperature are determined.
3. Flow balance satisfies with high-precision.
The total flow rate at a
node becomes zero for
any values of pressure.
The summation of flow rate for
internal nodes calculated by the
pressure becomes zero.
Internal node
q1 q2
q3q4
1 04
1
4
1
== ∑∑== α
αα
α φQQ
04
1
=∑=α
αq
Element
(C)Kentaro Taki, Kanazawa University
Hele-Shaw flow 2.5D model in cylinder
rRs
Rb
Ω
Rs: Screw radius
Rb: Barrel radius
θ
sz Rratvv === 0 ,0θ
bzb RratvRv ==Ω= 0 ,θ
z
vr = 0, vz and vθ are solo function of r.
(C)Kentaro Taki, Kanazawa University6
Geometry
(C)Kentaro Taki, Kanazawa University7
Shape function
( )4 4 4
1 1 1
, , , b s L sp p z z r R R Rα α α α α αα α α
φ θ φ θ φ ζ= = =
= = = = − +∑ ∑ ∑
( )( ) ( )( ) ( )( ) ( )( )1 2 3 4
1 1 1 11 1 , 1 1 , 1 1 , 1 1
4 4 4 4L L L L L L L Lφ ξ η φ ξ η φ ξ η φ ξ η= − − = + − = + + = − +
Element in cylindrical coordinate Element in computational coordinate
(C)Kentaro Taki, Kanazawa University8
Eq. of Continuity in cylindrical coordinate
( ) ( ) ( )1 10r zrv v v
t r r r zθ∂ρ ∂ ∂ ∂+ ρ + ρ + ρ =∂ ∂ ∂θ ∂
As ρ = constant and vr = 0,
( ) ( )10zv v
r zθ∂ ∂ρ + ρ =∂θ ∂
(C)Kentaro Taki, Kanazawa University9
Eq. of Motion
22
1 1v v pr
r r r r rθ θ ∂ ∂ ∂ η − = ∂ ∂ ∂θ
θ-component
( )2 2
2 2 2 2
2 1rv v v prv
r r r rr z rθ θ
θη η ηη
θ θθ∂ ∂ ∂∂ ∂ ∂ + + + = ∂ ∂ ∂ ∂∂ ∂
As steady state, ∂vθ/∂θ = ∂v
θ/∂z = 0, vr = 0,
(C)Kentaro Taki, Kanazawa University10
Eq. of Motion (Cont’)
1 zv pr
r r r z
∂∂ ∂ η = ∂ ∂ ∂
z-component
2
2 2 2
1 z z zv v v pr
r r r zr z
ηη ηθ
∂ ∂ ∂∂ ∂ + + = ∂ ∂ ∂∂ ∂
As steady state, ∂vz/∂θ = ∂vz/∂z = 0,
(C)Kentaro Taki, Kanazawa University11
Strain rate
2 2
1 1 11
2rc c
v pr
r r r r
∂ ∂ Ω Ω ≡ = − + ∂ ∂ &
θθγ
η θ γ γη
1 1
2cz
zrc
v pr
z z r
αγη β
∂ ∂ ≡ = − ∂ ∂ &
θr-component
zr-component
3
3
1 1, , ,
b b b b
s s s s
R R R R
c c c cR R R R
r rdr dr dr dr
r rα β γ δ
η η ηη= = = =∫ ∫ ∫ ∫
Integration constant
(C)Kentaro Taki, Kanazawa University12
Velocity
3 3
1 1 1
2 s s s
r r rc
R R Rc c
r p rv dr dr dr
r r rθβ
θ η γ γη η ∂ Ω = − + ∂ ∫ ∫ ∫
1 1
2 s s
r rc
z R Rc
p rv dr dr
z r
αη β η
∂ = − ∂ ∫ ∫
θ-component
z-component
3
3
1 1, , ,
b b b b
s s s s
R R R R
c c c cR R R R
r rdr dr dr dr
r rα β γ δ
η η ηη= = = =∫ ∫ ∫ ∫
Integration constant
(C)Kentaro Taki, Kanazawa University13
Flow rate
221
4 2b
s
Rc c
c bRc c
pq v dr Rθ θ
β βαθ γ γ
∂ Ω ≡ = − − + − ∂ ∫
21
4b
s
Rc
z z cRc
pq v rdr
z
αδβ
∂≡ = − − ∂ ∫
θ-component
z-component
3
3
1 1, , ,
b b b b
s s s s
R R R R
c c c cR R R R
r rdr dr dr dr
r rα β γ δ
η η ηη= = = =∫ ∫ ∫ ∫
Integration constant
(C)Kentaro Taki, Kanazawa University14
Flow balance of each element
15
( ) eeezee DpSSQ αβαβθ
αβα ++−=
dSDD
dSzz
SSdSSS
dqnqnQ
e
ee
e
S
e
S
zez
S
e
zze
∫
∫∫
∫
∂∂=
∂∂
∂∂=
∂∂
∂∂=
Γ+=Γ
θφ
φφθφ
θφ
φ
αθα
βααβ
βαθθαβ
θθαα
, ,
,)(
drr
drr
drr
drr b
s
b
s
b
s
b
s
R
Rc
R
Rc
R
Rc
R
Rc ∫∫∫∫ ====η
δη
γη
βη
α3
3 ,
1 ,
1 ,
−Ω=
−=
−=
c
cb
c
cc
z
c
cc
RD
SS
γβ
βαδ
γβα
θ
θ
2
22
2
,4
1 ,
4
1
Flow through a
node of element
Pressure-gradient
driven flow
Drag-force
driven flow
( )( ) ( )( ) ( )( ) ( )( )1 2 3 4
1 1 1 11 1 , 1 1 , 1 1 , 1 1
4 4 4 4L L L L L L L Lφ ξ η φ ξ η φ ξ η φ ξ η= − − = + − = + + = − +
(C)Kentaro Taki, Kanazawa University
Filled and unfilled calculation
16
Head press.
10MPa(given)
Press. at feed
0MPa(given)
Q = 20kg/h (Calc. result)
Q = 40kg/h (Calc. result)
Head press.
5MPa(given)Press. at feed
0MPa(given)
Completely filled screws
Partially filled screw
Head press.
5MPa(given)Press. at feed
0MPa(given)
Q = 20kg/h(given)
?
One degree of freedom is added.
(C)Kentaro Taki, Kanazawa University
Pressure downstream update scheme
17
Screw head position
Z
Screw inlet position
Z
1st step pressure distribution
Corrected pressure distribution
Z
Filling ratio distribution
f=0
f=1.0
FAN method (1D) 2.5D FEM
:Element to be renew
:Downstream elements
Pressure downstream update scheme
θθ
θθθ ∆∂∂−∆
∂∂−=∆−∆− p
zz
pzpzzp ),(),(
As the pressure is need to be determined according to the
two coordinates (z, θ), the pressure downstream update
scheme is developed.
(C)Kentaro Taki, Kanazawa University
Criteria of filled and unfilled
18
dp/dx<0
Pressure gradient Flow balance Fill or UnfillPressure
Q>Qd p>0 Filled1) fe=1
dp/dx>0 Q<Qd p>0 Filled2) fe=1
dp/dx>0 Q<Qd p<0 p=0 Unfilled3) fe=0
1) Q>Qd, unfilled state is impossible.
2) Q<Qd , p>0 : Filled sate and back flow (pressure gradient driven flow) is larger than the net flow.
3) Q<Qd , p<0 : Unfilled state and correction of p=0,W=fW are applied for FAM method (f=Q/Qd).
(C)Kentaro Taki, Kanazawa University
−=dx
dpWHHWVQ b
ηθ
12)2sin(
4
3
Pressure gradient driven flow, QpDrag-force driven flow Qd
Z
Fill ratio control line
∆∆=
∆=
∑ φφ
φφ
α
α cossin
sincos
Z
XD
XHVQ
D
aved
zd
∑=
zd
extz
Q
Qf
∑∑=
e
eeav
V
fVf
Correction of pressure distribution
z-axis fill ratio
determined by
screw geometry
↑Qext
Average fill ratio
determined by
pressure distribution
Adjusting pressure distribution to agree f av with f z.(C)Kentaro Taki, Kanazawa University
19
Performing simulation
Viscosity-strain rate model e.g., Cross model
Operation variables (Feed rate, Q, Head pressure P, Rot speed N)
Automatic meshing
Calculation of pressure distribution by FEM.
Fill ratio distribution
Simple wizard for constructing screw geometry
1E-3 0.01 0.1 1 10 100 1000100
1000
10000
180°C
190°C
200°CComplex viscosity [Pa·s]
Strain rate [s-1
]
(C)Kentaro Taki, Kanazawa University20
Effect of Screw Speed (rpm)
50 rpm
100 rpm
30 rpm
Decrease of screw speed expands filled region backwards.
Fill ratio
Un-filled Filled
Feed rate 0.75kg/h
head
(C)Kentaro Taki, Kanazawa University21
Effect of feed rate (kg/h)
Speed 30 rpm
Fill ratio
Un-filled Filled
0.25 kg/h
0.75 kg/h
0.50 kg/h
Increase of feed rate expands filled region backwards.(C)Kentaro Taki, Kanazawa University
22
Experiments
( ) 01
0*
, ,
1c
T Pηη γη γτ
−= +
&
&
0 exp273.15
bTa
Tη = +
1E-3 0.01 0.1 1 10 100 1000100
1000
10000
180°C
190°C
200°CCo
mp
lex
vis
cosi
ty [
Pa
·s]
Strain rate [s-1
]
Material
Homo polypropylene (F-704NP, Prime Polymer, Japan)
Viscosity-strain rate curve was obtained by the Cross model
Cross model
(C)Kentaro Taki, Kanazawa University23
Screw geometry and barrel temp.
Self-wiping co-rotating parallel twin screw extruder
L/D = 90, φ = 15 mm
(Technovel, Japan)
(C)Kentaro Taki, Kanazawa University24
Fill ratio distribution
30 rpm
0.5 kg/h
Fill ratio
Low (0) High (1)
Pulled-out screw
Simulation
(C)Kentaro Taki, Kanazawa University25
Screw speed (rpm) vs. Fill ratio
The calculation results
agree with the theoretical
definition, Q/Qd as the fill
ratio became half when the
screw speed becomes
double.
x2
x0.5
(C)Kentaro Taki, Kanazawa University26
40 60 80 100 1200.0
0.1
0.2
0.3
Calc.
Fil
l ra
tio
[-]
Screw rotational speed [rpm]
Feed rate vs. fill ratio
Calculation agrees with
the theoretical definition
of fill ratio, Q/Qd as the
plots exist on the straight
line from origin.
(C)Kentaro Taki, Kanazawa University27
0.0 0.2 0.4 0.6 0.8 1.0 1.2
0.0
0.1
0.2
0.3
0.4
Calc.
Fil
l ra
tio
[-]
Feed rate [kg/h]
Throughput vs. fill ratio
Calculation agrees with
the theoretical definition
of fill ratio, Q/Qd as the
plots exist on the straight
line from origin.
(C)Kentaro Taki, Kanazawa University28
0.0000 0.0025 0.0050 0.0075 0.01000.0
0.1
0.2
0.3
0.4
Calc.Fil
l ra
tio
[-]
Feed rate and Rotational spped ratio, Q/N [kg/(h rpm)]
Conclusion
• We achieved a development of 2.5D Hele-Shaw model for
calculation of pressure distribution in twin screw extruder.
• This model has advantage for short-calculation time, possible
to whole screw elements.
• The fill ratio was calculated based on the FAN method.
• Further experimental validations not only the fill ratio but also
fiber attrition, plasticization etc are demanded.
• Devolatilization model will be added.
(C)Kentaro Taki, Kanazawa University29
Contact information
• This software is proprietary and commercially available by the
HASL Co. ltd., Japan.
• Please contact
– Dr. Shin-ichiro Tanifuji, CEO of HASL.
– URL: http://www.hasl.co.jp
– E-mail: [email protected]
Thank you for your kind attention.
CEO Dr. Shin-ichiro Tanifuji
(C)Kentaro Taki, Kanazawa University30