Computational analysis and design of single screw extruders having screws of complex geometry with mixing elements

The methodology is based on some conventional models for flow in the hopper, solids bed and melting zone. In the melt pumping zone the Hele - Shaw approximation is applied, which describes spreading flow in two dimensions. The momentum and energy equations are solved layer - by - layer starting from the barrel wall. This methodology enables significant reduction of computer time required for simulation of extruders with complex screw geometry, over the fully 3D approach. Good agreement was obtained with some available experimental data and further evaluations of predictive capabilities are currently underway.