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The co-rotating twin screw extrusion process is widely employed in chemical industries for the processing of complex fluids including various polymers, suspensions, emulsions and gels. Here we propose a new integrated modeling strategy that is based on the numerical analysis of pressure-generating extrusion elements concomitantly with the pressure-losing extrusion elements of the co-rotating twin screw extrusion process for non-Newtonian fluids under nonisothermal conditions. The numerical analysis undertakes three-dimensional (3-D) finite element simulations of any multiple combinations of forwarding and reversing fully-flighted screw elements with other types of elements including kneading discs staggered in the forward or reverse configurations and the die. The abilities of the methodologies in simulating the coupled flow and heat transfer in industrially-relevant mixing sections or pressurization/die shaping are demonstrated with predictions of the degree of fill and typical velocity, deformation rate, stress magnitude, pressure distributions as functions of various operating parameters and basic twin screw extrusion geometries for a viscoplastic type generalized Newtonian fluid.

An Integrated Approach for Numerical Analysis of Coupled Flow and Heat Transfer in Co-rotating Twin Screw Extruders