Computer Flow Simulation of Moffatt Eddies in Single Screw Extrusion

Abstract A 3D flow analysis package is used to simulate the flow phenomena in a short section of the metering zone of a single screw extruder. The assumption of stationary screw and rotating barrel is used. For sharp flight root corners, in addition to the primary flow field a secondary flow was determined in front of the root of the pushing flight and behind the root of the trailing flight, akin to what is known in the fluid mechanics literature as Moffatt eddies. Fluid particles caught in Moffatt eddy regions require travel times which are at least two orders of magnitude larger than the average residence time. This implies high probability of degradation and explains the deposits of thin carbonaceous films and gels, which have been discussed in several publications in the technical literature. The computer simulations show the existence of Moffatt eddies in the presence or absence of pressure gradients. When the screw roots have relatively wide angles no Moffatt eddies are predicted, in agreement with recommendations for good screw design practices.