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INTRODUCTION
here has been a substantial amount of work on the
T a n a l y s i s and mathematical modelling of flow in screw
pumps (extruders); the characteristics of most approaches are summarized in Table 1 of Ref. (1).Models
which have most closely approached the real situation
have necessarily involved numerical solution of the governing differential equations. Pre-eminent in this category is the work of Griffith (2), Pearson, et al. (3)and
Fenner (4), who used finite difference methods and a
Cartesian coordinate system with the unwrapped channel approximation. The main features of the mathematical models used in these works have been summarized
(1)and it is not necessary to repeat them here. More
recently the work of Fenner and Palit (5-7) provides an
instance where the finite element method has been
used; the unwrapped channel approximation was,
however, retained. Solutions were obtained for twodimensional developed isothermal flow of power law
fluids. Non-isothermal solutions (5)were hampered by
the lack, at that time, of a true finite element analogue of
the finite difference technique of up-wind differencing,
which is required to deal with convective heat transfer at
higher Peclet numbers.
The present work follows on from Ref. (l),where a
variational analysis was set u p in helical coordinates,
and it differs from previous approaches in combining the
following three features:
The true geometry of the channel is taken into
consideration.
The finite element method is used.
Computed results are compared in detail with data
from carefully controlled experiments.
POLYMER ENGlNEERlNG AND SCIENCE, MARCH, 1980, Vol. 20, No. 5
ing
The case for the finite element method in mot
polymer processing has been made elsewhere (1,7, lox
and Pearson (11)has suggested that it might be used in
what we could describe as the ultimate approach to the
plasticating extruder problem. The case extends to all
situations where the geometry of the problem is one of
the parameters which we wish to vary, and where the
domain of the problem may not be a simple shape.
Although comparisons are hard to come by, it seems that
modern finite element techniques can be more efficient
in terms of computer usage than finite difference techniques. Certainly in terms of the sum of human-plusmachine effort, the ease with which a finite element
program can be applied to a whole range of problems
gives important benefits. A proposal to use finite elements in the present context was made in Ref. (1)and
the work of Pallit and Fenner represents the only example of its application to date in the extrusion problem.
Conclusive comparisons between numerical solutions
and experimental results are not abundant in this field.
The available data on extruder performance can be divided into two categories; those obtained under practical conditions and those from idealized experiments. In
the practical category, data are typically measured on
highly instrumented extruders pumping molten polymer (and probably also conveying and melting). Conditions are far removed from isothermal: flow is never fully
developed, and the fluid is highly non-Newtonian, with
considerable doubt existing as to the appropriateness of
any particular constitutive equation in this nonviscometric flow field. The possibility of wall slip exists
(12) and the flight may strip melt from the barrel (13).
Accurate data on physical properties and boundary con339
+ -u . V (P + p a ) + po
r
A:A
dV (1)
k
- (VT) 2
po
(%)TI dV
(2)
Finite Element Solutions for Flow in a Single Screw Extruder, Including Curvature Effects
compressible velocity fields are indeed the momentum
conservation equations for a generalized Newtonian
fluid. /I.,, is the local viscosity value, and for nonisothermal flow provides coupling with the energy functional. The energy functional is a modification of that
derived previously (1)and is more convenient in that the
field variable is in the denominators. It is identical to the
form used by Palit (5), and again it is easy to show (17)
that the Euler Lagrange equations give the correct
energy-conservation relationship. The functional does
not include provision for stored elastic energy, consistent with the assumption of a purely viscous flow.
The helical coordinate system which has been used is
as follows:
(1)Radius, r , measured from the screw axis.
(2) Helical distance, s, measured along the intersection of a cylinder of radius r and a helical reference
surface fixed relative to the barrel, coaxial with it, and
with the same pitch and sense as the screw.
(3) Axial distance, t, measured from the reference
helix.
The coordinates are dimensionless, having been
scaled by the barrel internal radius R. The helical reference surface is thus the coordinate plane t = 0. s = O is a
plane passing through the axis and fixed relative to the
barrel. The system is non-orthogonal and is illustrated in
Fig. 1 . It differs from that previously used by Zamodits
(8) for the extruder problem, and from that proposed by
Tung and Lawrence (18) for the treatment of flow in
static mixers, etc. The latter states that the coordinate
transformations given in our previous paper (1)do not
give the coordinate curves we describe, that our vector
component transformations do not follow the rules for
contravariant components, and that our continuity equation is incorrect. We are therefore obliged to go into
some detail to clear up this misunderstanding. In their
paper, Tung and Lawrence review some standard material on general curvilinear coordinate systems, and go on
to derive equations of motion and continuity using the
general laws for contravariant component transformations. Their remarks about our work show that they have
assumed that we are also using contravariant components. In fact, this is not the case; our system is mixed.
Ours base vector is tangential to the intersection of the r
= constant and t = constant surfaces, and is thus a
natural base normalized to unit magnitude; likewise the
t-direction base, which is tangential to the intersection
of r = constant and s = constant. The r components,
however, are not referred to a unit vector tangential to
the intersection ofs = constant andt = constant. We use
instead a base orthogonal to the s and t bases just mentioned. It is thus a reciprocal rather than a natural base
(see Fig. 1).An attempt to derive our component transformations or continuity equation assuming a system of
natural base vectors, as Tung and Lawrence appear to
have done, will inevitably fail. In fact, we avoided their
approach and derived our results by the simple and
direct method which is given in the Appendix. We
denote dimensional velocity components by u:, u i , u l ,
and scale these by 2 rrRN to obtain dimensionless components u T ,us,ut.
POLYMER ENGINEERING AND SCIENCE, MARCH, 1980, Vol. 20, No. 5
axial
pitch
r, s, t.
to the axis/R
to the axid2rrR
u, = us = ut = 0
k { D } [L,]{Dq)drdt (4)
P*
1 u. +
V(P
p a ) dV =
V u(P + p a ) dV
ut =
d k4' + 1-2
k4
Q~~ =
!,I,2 T ~ N3 [
drdt
(6)
342
Finite Element Solutions f o r Flow in a Single Screw Extruder, Including Curvature Effects
To get the throughput of the machine, one has to correct
this channel flow rate by the amount of leakage over the
flight. Expressions are given elsewhere (17)in terms of
the helical system for the drag and pressure-driven
components of the leakage flow. However, since the
'clearance is generally very small, leakage can be
adequately calculated for the isothermal Newtonian case
using the analysis by Mohr and Mallouk (19) which
neglects curvature. This is also true for the simplest form
of non-Newtonian isothermal flow.
Results will be presented later in terms ofdimensionless flow rate and axial pressure gradient, as used by
Fenner (4).These were originally defined in terms of a
Cartesian representation and are interpreted here as
follows:
rIQ=
Q
2mRNWH
COS'
&,
(7)
Y=
2mRN cos
H
~$b
YM = Y M + a/v(V.U),dV
(9)
drdt
(10)
a=
variational derivative of YM
variational derivative
/ (V -
(11)
u)'dV
Assembly of the element contributions gives the extremalizing conditions, to be solved for the totality of
unknowns {u}:
u
au,
L+
r
dr
au,
- - 0,
at
element vol
(16)
344
(15)
The sums over the whole mesh for the shallow (256
Table 1. Deep Screw Dimensions
Barrel internal radius, R, rnrn
19
rnrn
Barrel axial length, rnrn
1000
rnrn
Axial channel width, W, rnrn
109
rnrn
Channel depth, H, rnrn
9.6 rnrn
Axial pitch, rnrn
121
rnm
11.9 rnrn
Axial flight width, rnrn
Flight clearance, rnrn
0.18 rnm
Helix angle at radius R, 4,,, deg 45.2
HIW
0.087
HiR
0.506
Finite Element Solutions f o r Flow in a Single Screw Extruder, Including Curvature Effects
1.4
1.2
1.0
us
.5
.6
:9
1c3
1 o5
1I
1 c6
1 0
u poise-
1.2
1.0
I
.E
.6
4
.2
102
103
t@
105
a poise-
Id
106
16
Q
in3513
+,,
1 r,J
10
1 g4
a
106
13
poci
elements) and the highly curved channel (1024 elements) were 0.16 x lop4and 0.05 x lo-, respectively.
Inspection of the element values showed that the largest
values occurred near the flight clearance, indicating that
POLYMER ENGINEERING AND SCIENCE, MARCH, 1980, Vol. 20, No. 5
0.78 (25%)
FDC
FpC
= 0.97 (t5%)
M . L. H a m i and J. F . T . P i t t m a n
depth in the channel. In the present case,
APPENDIX
The Helical System
w,,,~ = W cos 51 = 68 mm
H/wmean
= 0.14 and the factors are (31)
so
Fp
= 0.9 (25%)
FD = 0.92 ( t 5 % )
The resulting operating line is shown in Fig. 7, together
with the one-dimensional unwrapped channel results (based on barrel diameter and helix angle) and the
computed solution. In this example, the Booy correction
slightly overestimates the reduction in flow rate and
pressure-raising capacity due to curvature. The present
computer method clearly has the potential for a more
extensive investigation of curvature effects, and comparison with other results which attempt to correct for
channel curvature (2, 33-36).
None of the flow rates discussed above, either analytic
or computed, has been corrected for leakage flow over
the flights. This topic will also be taken up subsequently.
CONCLUSION
Finite element solutions for developed isothermal
Newtonian flow in both shallow and deep highly curved
screw channels have been obtained, based on a variational formulation in helical coordinates. An integral
constraint method has been used to enforce continuity,
and the dependence of the solutions on Lagrangian multiplier value has been investigated. It is found that for
sufficiently fine meshes, a clear range exists where the
solution is independent of the multiplier value. This
range is a function of geometry and mesh design, and not
of the boundary conditions or physical properties of the
problem. Solutions obtained within the region of multiplier independence are shown to converge to analytic
solutions for a wide, shallow channel. Solutions for a
deep, curved channel show a smaller reduction of
throughput due to curvature than is predicted by the
Booy correction. Computations for this case will be subsequently tested against experimental results.
xl/R -
X2
-.
2rr
271. Vx,
+ k4 R2 = Rs
(A-1)
Therefore,
x2
* 27Tk4R =Rt -
Also,
277
x3
t = x2k, + 2R
X
Therefore,
(-4-3)
Derivatives. Suppose a scalar (or vector/tensor component) F is expressed in the two coordinate systems:
Then
F = f l i X 1 , x2, x 3 ) = fib-,s, t )
aF - aF dr +--+-dF as
aF at
ax,
dr ax,
as ax,
a t ax,
(A-4)
Therefore,
Similarly,
aF - 1 dF
- -R ar
ax,
rs
R(k$ + r)
aF
as
aF aF + k p aF
- - V k 2 + r2 ax2
as
at
(A-5)
0.5
0.4
and
c.3
0.2
ii.1
(-4-6)
u .b,, we obtain
Taking in turn the dot products POLYMER ENGlNEERING AND SCIENCE, MARCH, 1980, Vol. 20, No. 5
Finite Element Solutions f o r Flow in a Single Screw Extruder, lncluding Curvature Effects
241
(A-7)
= u:
u, = u: cos
(7d2 +
4)
rate
p_
= density
= helix angle
4 b
v3
= u; cos
4 + u;
Greek Scalars
= Lagrangian multiplier
= a characteristic shear rate
= a dimensionless measure of continuity en-
forcement
= viscosity
= reference viscosity
= a characteristic viscosity, applicable at
shear rate
= dimensionless extruder pressure gradient
= dimensionless extruder volumetric flow
POLYMER ENGINEERING AND SCIENCE, MARCH, 1980, Vol. 20, No. 5
{ ] (px1)
n1
Vectors, Tensors
= del operator
Subscript
0
=indicates values which render the functional stationary, i.e., indicates terms not
subject to variation
REFERENCES
348