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Area of Science:

  • Polymer Science
  • Fluid Dynamics
  • Materials Engineering

Background:

  • Vortical flows are known in fluid dynamics.
  • Fountain flows are associated with injection molding.
  • Single-screw extrusion processing exhibits variances.

Purpose of the Study:

  • Investigate variances in single-screw extrusion.
  • Identify novel flow phenomena in plasticating screws.
  • Understand the causality of observed processing variances.

Main Methods:

  • Empirical evidence via screw freezing experiments with high-impact polystyrene (HIPS) and colorants.
  • Process modeling using non-isothermal, non-Newtonian simulations.
  • Analysis of melt channel dynamics adjacent to the solids bed.

Main Results:

  • Empirical evidence and simulations suggest vortical fountain flows in melt channels.
  • Increased flow conductance due to higher temperatures and shear rates in recirculating melt pools.
  • Development of persistent, coiled sheet morphologies in various screw designs.
  • Broader residence time distributions compared to prior models.

Conclusions:

  • Vortical fountain flows represent a significant factor in polymer processing variances.
  • Understanding these flows can guide strategies for improved dispersion and microstructure control.
  • This finding challenges existing polymer melting and plastication models.