In many extrusion processes, the metering section is the rate-controlling part of the screw. In this functional zone, the polymer melt is pressurized and readied to be pumped through the die. We have recently proposed a set of heuristic models for predicting the flow behavior of power-law fluids in two- and three-dimensional metering channels. These novel theories remove the need for numerical simulations and can be implemented easily in practice. Here we present a comparative study designed to validate these new methods against experimental data. Extensive experiments were performed on a well-instrumented laboratory single-screw extruder, using various materials, screw designs, and processing conditions. A network-theory-based simulation routine was written in MATLAB to replicate the flow in the metering zones in silico. The predictions of the three-dimensional heuristic melt-conveying model for the axial pressure profile along the screw are in excellent agreement with the experimental extrusion data. To demonstrate the usefulness of the novel melt-flow theories, we additionally compared the models to a modified Newtonian pumping model known from the literature.

Numerous analyses have modeled the flow of polymer melts in the melt-conveying zones of single-screw extruders. While initial studies mainly provided exact analytical results for combined drag and pressure flows of Newtonian fluids, more recently developed, numerical methods seek to deepen the understanding of more realistic flow situations that include shear-thinning and non-isothermal effects. With the advent of more powerful computers, considerable progress has been made in the modeling and simulation of polymer melt flows in single-screw extruders. This work reviews the historical developments from a methodological point of view, including (1) exact analytical, (2) numerical, and (3) approximate methods. Special attention is paid to the mathematical models used in each case, including both governing flow equations and boundary conditions. In addition, the literature on leakage flow and curved-channel systems is revisited.

To enable the use of recyclates in thermoformed polypropylene products with acceptable optical appearance and good mechanical stability, a multilayer structure of virgin and recycled material can be used. When producing multilayer films with more than two layers, the used materials should have similar melt flow properties to prevent processing instabilities. In the case of a three-layer film, post-consumer recyclates are often hidden in the core layer. Due to the inconsistent melt flow properties of post-consumer recyclates, the adjustment of the melt flow properties of the core layer to those of the outer layers has to be realized by blending with virgin materials. In order to understand the effect of mixing with a virgin material with a certain pre-defined melt flow rate (MFR), material mixtures with different mixing partners from various sources were realized in this study. Hence, the pre-defined virgin material was mixed with (i) virgin materials, (ii) artificial recyclates out of a mixture of different virgin materials, and (iii) commercially available recyclates. These blends with mixing partner contents ranging from 0–100% in 10% increments were prepared by compounding and the MFR of each mixture was determined. For a mathematical description of the mixing behavior and furthermore for a proper MFR prediction of the material mix, existing mixing rules were tested on the three pre-defined sample groups. Therefore, this paper shows the applicability of different mixing rules for the prediction of the MFR of material blends. Furthermore, a new mixing rule was developed using symbolic regression based on genetic programming, which proved to be the most accurate predictive model.

Generally, numerical methods are required to model the non-Newtonian flow of polymer melts in single-screw extruders. Existing approximation equations for modeling the throughput–pressure relationship and viscous dissipation are limited in their scope of application, particularly when it comes to special screw designs. Maximum dimensionless throughputs of ${\mathsf{\Pi }}_V<2.0$ , implying minimum dimensionless pressure gradients ${\mathsf{\Pi }}_{p,z}\ge -0.5$ for low power-law exponents are captured. We present analytical approximation models for predicting the pumping capability and viscous dissipation of metering channels for an extended range of influencing parameters ( ${\mathsf{\Pi }}_{p,z}\ge -1.0$ , and $t/D_b\le 2.4$ ) required to model wave- and energy-transfer screws. We first rewrote the governing equations in dimensionless form, identifying three independent influencing parameters: (i) the dimensionless down-channel pressure gradient ${\mathsf{\Pi }}_{p,z}$ , (ii) the power-law exponent $n$ , and (iii) the screw-pitch ratio $t/D_b$ . We then carried out a parametric design study covering an extended range of the dimensionless influencing parameters. Based on this data set, we developed regression models for predicting the dimensionless throughput-pressure relationship and the viscous dissipation. Finally, the accuracy of all three models was proven using an independent data set for evaluation. We demonstrate that our approach provides excellent approximation. Our models allow fast, stable, and accurate prediction of both throughput-pressure behavior and viscous dissipation.