Analysis of the performance of plasticating single‐screw extruders with a new concept of solid‐bed deformation

The performance of plasticating single‐screw extruders is analyzed by combining three functional sections: (a) solids‐conveying section, (b) melting section, and (c) melt‐conveying section. In the analysis of the melting section, we have incorporated a new concept of solid‐bed deformation (i.e., the rheology of the solid bed) into Lindt‐Elbirli's analysis and included convective heat transfer in the energy equation. Specifically, we have computed stresses on the surfaces of the solid bed, which is surrounded by thin melt films and a melt pool, and, also, computed the apparent modulus of the solid bed in the bulk state as a function of temperature and position within the solid bed, along the extruder axis. From this information, we were able to compute the extent of solid‐bed deformation, by assuming a linear stress‐strain relationship as the constitutive equation of the solid bed. In this approach, we do not assume a priori whether the solid bed is rigid or freely deformable. The solution of the system equations gives us the following information: (a) whether or not the solid bed deforms and if it does, then, how much; (b) the solid‐bed velocity along the extruder axis; (c) pressure profiles along the extruder axis; (d) solid‐bed profiles in the melting zone along the extruder axis; (e) temperature profiles along the extruder axis; (f) velocity and temperature distributions in the melt pool along the extruder axis; and (g) thicknesses of thin melt films surrounding the solid bed. Theoretically predicted solid bed and pressure profiles along the extruder axis are compared with experimental results reported in the literature. We have pointed out an urgent need for measurements of the apparent modulus of the solid bed in the bulk state as a function of temperature and pressure, under a combined shear/drag flow field.