Experimental validation of numerical simulations of the kneading disc section in a twin screw extruder

Abstract A comparison of the results of a 3D model for the simulation of flow in the kneading disc region of a fully intermeshing twin screw extruder has been done against particle image velocimetry (PIV) experimental data. Experimental results using a geometry with an extended first and last kneading disc to capture the simplified inlet and outlet boundary conditions, are in good qualitative agreement for low flow rates. The results showed good agreement at flow rates less than 5 mL/s and rotation speeds of 60 rpm, while above that there was poor agreement. These results highlight the importance of the use of appropriate boundary conditions for the accurate prediction of the flow field. The flow field within the kneading discs with forward conveying elements placed before and after the kneading discs was also measured. For a flow rate of 8.5 mL/s and 60 rpm, results showed good agreement when conveying elements were deployed before and after the kneading blocks whereas for lower flow rates there was poor agreement.