Design and Optimization of Wave-Dispersion Screws

单螺杆挤出机是聚合物加工工业中最重要的机械。在塑化挤出过程中，聚合物以固态进料到挤出机中，当材料通过旋转的挤出机螺杆从进料口输送到模头时，材料熔化。根据经济框架，机器制造商的主要目标是在保证高熔体质量的同时提高产量。满足这些要求需要适当的螺杆设计，从而彻底了解控制挤出过程的传输现象。该牵头机构的研究项目侧重于固体床破碎螺杆概念，将详细研究波分散螺杆。为了增加对波分散螺杆中复杂过程的理解，将在3D-CFD-Simulations的帮助下开发新的过程模型，并通过在光滑机筒（KTP）和开槽机筒（IPEC）单螺杆挤出机上进行的实验研究进行验证，涵盖广泛的可能挤出工艺。这将增加波分散螺杆的建模精度相比，现有的简化模型的过程行为，从而使潜在的螺旋波分散螺杆的优化，使他们可以充分发挥其potential.Hypothesis和方法：3D-CFD-Simulations将在两种不同的方式进行。一方面，数据驱动的压力/吞吐量模型是通过许多熔体主导的弯曲螺杆通道模拟生成的。另一方面，一个非等温的三维计算流体力学模拟模型，它也考虑了固体材料的熔化，介绍和用于分析不同的波分散螺杆。此外，设计指南的常见材料类型的波分散螺杆上处理的开发。这将有助于满足单螺杆挤出领域对产量和熔体质量的高要求。此外，还将在各种45 mm单螺杆挤出机上进行实验研究，以验证这些模型。创新性和新奇：涉及上述主题的少数科学论文仍有许多问题没有得到解答，表明本提案的内容具有高度相关性。研究表明，波分散型螺杆具有较高的生产能力和较好的熔体均匀性，但螺杆设计的解析计算模型精度不高。由于所研究的螺杆概念必须精心设计，以充分发挥其优势，目的是将KTP，Paderborn和IPEC，林茨的建模和模拟领域的专业知识合并，以产生新的建模方法，大大提高预测的准确性。因此，一个成功的和可靠的设计和使用的波分散螺杆将是可能的。

Content:Single-screw extruders are indisputably the most important machines in the polymer processing industry. During plasticating extrusion, polymer is fed to the extruder in the solid-state and the material is melted as it is conveyed by the rotating extruder screw from the feed port to the die. Based on the economic framework, the primary objective of machine manufacturers is to increase the output capacity while guaranteeing high melt quality. Meeting these demands requires proper screw design and thus a thorough understanding of the transport phenomena governing the extrusion process. Focusing on solid bed breaking screw concepts, this lead-agency research project will investigate wave-dispersion screws in detail. To increase the understanding for the complex processes in wave-dispersion screws, new process models will be developed with the help of 3D-CFD-Simulations and validated by experimental studies carried out on smooth-barrel (KTP) as well as grooved-barrel (IPEC) single screw extruders, covering a wide range on possible extrusion processes. This will increase the modeling accuracy of wave-dispersion screws in comparison to existing simplified models of the process behavior and thus give potential for screw optimization of wave-dispersion screws so that they can exploit their full potential.Hypothesis and methods:3D-CFD-Simulations will be carried out in two different ways. On the one hand, a data driven pressure/throughput model is generated by means of many melt-dominated curved screw channel simulations. On the other hand, a non-isothermal 3D-CFD simulation model, which also considers the melting of the solid material, is introduced and used for the analysis of the different wave-dispersion screws. Furthermore, design guidelines for common material types processed on wave-dispersion screws are developed. This will help to meet the high demands in terms of output capacity and melt quality in the field of single-screw extrusion. Additionally, experimental studies will be carried out on various 45mm single-screw extruders to validate these models.Innovation and novelty:The few scientific papers dealing with the above-mentioned topic still leave many questions unanswered and show that the contents of this proposal are highly relevant. It has been shown, that wave-dispersion screws can lead to higher throughput and better melt homogeneity, but the analytical calculation models for designing a screw have a lack of precision. Since the investigated screw concept must be meticulously designed in order to unfold its full advantages, the aim is to merge the expertise in the field of modeling and simulation of the KTP, Paderborn and the IPEC, Linz to produce new modeling approaches that considerably increase the accuracy of the predictions. As a result, a successful and trustful design and use of the wave-dispersion screws will be possible.