Solution to Chemical Engineering Question - Extruder

Given:
channel depth H = 2.4 mm = 0.0024 m
channel width T = 45 mm = 0.045 m
screw length L = 1000 mm = 1 m
screw diameter D = 50 mm = 0.05 m
screw speed N = 100 rev/min = 1.667 rev/sec
flight angle = 17o 42' = 17.7o
plastic viscosity h1 = 200 N-s/m2 and h2 = 400 N-s/m2
lace die radius R = 3/2 mm = 1.5 mm = 0.0015 m
lace die length Ld = 40 mm = 0.04 m
dP
Pressure gradient = 20 MN/m2 or 20 ´ 106 N/m2
dL

Solution:
Die Characteristics:

The output flow of a fluid from a die is directly proportional to pressure as is given by the
following equation

Q = KP
4
pR
where K = for a single capillary die of radius R and length Ld. Substituting values,
8hLd
for the two different viscosities:

æ p(0.0015)4 ö÷
Q1 = ççç ( )
÷ (P ´ 1000000) = 2.485 ´ 10-7 P
çè 8(200)(0.04)÷÷ø
æ p(0.0015)4 ö÷
Q2 = ççç ( )
÷÷ (P ´ 1000000) = 1.2425 ´ 10-7 P
çè 8(400)(0.04)÷ø

where Q is in m3/s and P is in MPa. Notice that Q1 is twice more than Q2 when viscosity
is doubled from 200 N-s/m2 to 400 N-s/m2.

Extruder Characteristics:

When the pressure at the end of the extruder is large enough to stop the output, the
maximum pressure possible is given as follows

For h1 = 200 N-s/m2:

6ph1LDN 6p(200)(1)(0.05)(1.667)
Pmax = 2
= 2
= 170.9 ´ 106 Pa = 170.9 MPa
H tan f (0.0024) tan(17.7)
For h2 = 400 N-s/m2:
6ph2LDN 6p(400)(1)(0.05)(1.667)
Pmax = 2
= 2
= 341.8 ´ 106 Pa = 341.8 MPa
H tan f (0.0024) tan(17.7)

Notice that the maximum pressure is doubled when the viscosity is also doubled.

Assuming that there is no pressure buildup at the end of the extruder, the maximum flow is
given by the following equation:
1
Qmax = p 2D 2NH sin f cos f
2
1
= p 2 (0.05)2 (1.667)(0.0024)sin(17.7)cos(17.7)
2
= 1.429 ´ 10-5 m 3 /s
Notice that is not a function of viscosity so it remains the same when the viscosity is
doubled.

We now construct a Q vs P plot with the following set of equations

For h1 = 200 N-s/m2:

(i) Die Characteristics
(
Q1 = 2.485 ´ 10-7 P )
(ii) Extrude Characteristics:
Pmax = 170.9 MPa  
Qmax = 1.429 ´ 10-5 m 3 /s

For h2 = 400 N-s/m2:

(i) Die Characteristics
(
Q2 = 1.2425 ´ 10-7 P )
(ii) Extrude Characteristics:
Pmax = 341.8 MPa  
Qmax = 1.429 ´ 10-5 m 3 /s  
Note that the point of intersection of the die and extruder characteristics is operating point
whose coordinates is the operating flow rate and operating pressure. Based on the plot,
when the viscosity is 200 N-s/m2 the operating point is approximately P = 43 MPa or 43
MN/m2 and V = 1.075 x 10-5 m3/s. One the other hand, when the viscosity doubles to 400
N-s/m2, the new operating point is approximately P = 85 MPa or 85 MN/m2 and V = 1.075
x 10-5 m3/s. Increasing the viscosity results to an increase in operating pressure while the
operating flow is unchanged.

Solution By JamesDL33 CourseHero Tutor 1/15/2021