A Model to Predict the Flow Rate in Single Conical Screw Extruder

ABSTRACT A novel general model for predicting the flow rate and pressure in conical screw extruders for polymer processing has been developed, addressing a crucial need in polymer manufacturing. Based on single screw extruder flow Equations and mass conservation principles, we derived a flow rate Equation for a single conical screw, accounting for variations in screw diameter and slot depth along the length. Recognizing the significant impact of slip phenomena on flow rates, especially for energetic materials, we incorporated a slip velocity correction for non‐Newtonian fluids. This correction was based on simulations across various diameters and rotational speeds, enhancing the model's accuracy for real‐world polymer extrusion processes. The model's predictive power was validated through experimental data, yielding impressive accuracy with simulation calculation errors of 1.59% and numerical derivation errors of 7.40%. This research bridges the gap between theoretical polymer rheology and practical extrusion processes, offering a method for optimizing the design technology of single conical screws.