REGULAR CONTRIBUTED ARTICLES
N. D. Polychronopoulos1 *, J. Vlachopoulos1,2
1 Polydynamics Inc., Dundas, Ontario, Canada
2
Department of Chemical Engineering, McMaster University, Hamilton, Ontario, Canada
Computer Flow Simulation of Moffatt Eddies
in Single Screw Extrusion
A 3D flow analysis package is used to simulate the flow phe-
nomena in a short section of the metering zone of a single
screw extruder. The assumption of stationary screw and rotat-
ing 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 me-
by McMaster University on November 27, 2018. For personal use only.
chanics 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 ex-
plains the deposits of thin carbonaceous films and gels, which
have been discussed in several publications in the technical
IPP 2018.33:662-668.
literature. The computer simulations show the existence of
Moffatt eddies in the presence or absence of pressure gradi-
ents. When the screw roots have relatively wide angles no
Moffatt eddies are predicted, in agreement with recommenda-
tions for good screw design practices.
1 Introduction
The single screw extruder is the workhorse of the polymer pro-
cessing industry. Polymer pellets, flakes or powder are fed into
a heated barrel in which an Archimedean screw rotates. The
solid polymer particles are compacted as they are transported
forward, melted and pumped through a die for the purpose of
shaping into the desired product. The operating principles of
the so-called plasticating screw extruder have started to be un-
derstood after the publication of a series of papers in the early
1950’s by a DuPont team (Gore, 1953; Carley and Strub,
1953a; 1953b; Carley et al., 1953; McKelvey, 1953; Mallouk
and McKelvey, 1953; Carley and McKelvey, 1953; Jepson,
1953) and, independently, a doctoral thesis by Maillefer
(1952). Further research work by Maddock (1959), Tadmor
(1966) and numerous other investigators, as summarized by
Tadmor and Gogos (2012), Chung (2000) and Spalding and
Campbell (2013) laid the foundations for modern extruder
technology. The understanding of the solids transport, melting
* Mail address: Nickolas D. Polychronopoulos, Polydynamics Inc,
102 Plaza Dr., P.O. Box 63067, Dundas, Ontario, Canada L9H
6Y3
E-mail: polyrheo@polydynamics.com
662  Carl Hanser Verlag, Munich Intern. Polymer Processing XXXIII (2018) 5
and pumping led to several innovations in screw and barrel de-
signs, such as barrier screws, screws with mixing sections and
grooved barrels as explained by Rauwendaal (2014). The pur-
pose of these design innovations is to increase the output rate
of stable, high quality melt, free from unmelts and degraded
material.
It has been known for a long time that polymers may degrade
in the screw channels as a result of long residence times under
high temperatures, mainly due to frictional heat generation
(viscous dissipation) and to a lesser extent to external heating.
Spalding and co-workers in several conference presentations
and publications (Spalding et al., 1999; Spalding and Gou,
2015; Spalding, 2015; Spalding et al., 2015) provided signifi-
cant evidence that polymers may degrade by forming a carbo-
naceous thin film at the base of screw flights having small
radii, that it can be dislodged and produce black specs in ex-
truded film. They attributed the degradation process to Moffatt
eddies (Moffatt, 1964). Moffatt eddies are secondary vortex
flows which form in sharp corners. Numerically, it is very easy
to demonstrate such vortices in two-dimensional lid-driven
cavity flows. In fact, this flow type is frequently used as the
benchmark problem for new numerical methods and techni-
ques, for different Reynolds number ranges, and occasionally
for viscoelastic fluids. Typically, the top of four walls of a
square cavity (two-dimensional) moves, dragging the top of
the fluid, causing a primary recirculation and secondary flows
at the two bottom corners (Sousa et al., 2016).
In screw extrusion, the flow field is usually analyzed by as-
suming a stationary screw and a rotating barrel. With this as-
sumption the moving barrel is dragging the polymer towards
the screw flights, at an angle determined by the flight helix an-
gle and the flow field is three-dimensional. Fodor and Kauf-
man (2015) demonstrated the generation of Moffatt eddies in
a corner of a screw channel by imposing an analytical velocity
profile for combined drag and pressure flow in the longitudinal
direction and velocities extracted from a numerical simulation
in the other two directions. In the present investigation, the
flow field is generated within the computational scheme by
the dragging action of the rotating barrel for three different
conditions: (a) Without a die at the end of the extruder, which
means that for a suitably designed screw the output will be
equal to that predicted by the drag flow equation (Tadmor,
1966). (b) With a die at the end of the extruder causing an ad-
verse pressure gradient and output rate below that predicted
by the drag flow equation. (c) Assuming the extruder barrel is
 N. D. Polychronopoulos, J. Vlachopoulos: Computer Flow Simulation of Moffatt Eddies
grooved in the feed zone resulting in high pressure, which im-
plies an aiding pressure gradient in the metering zone and out-
put rate higher than that predicted by the drag flow equation.
These assumptions are fully in agreement with current extru-
sion practices. The question of whether the simplifying as-
sumption of stationary screw and rotating barrel impacts ex-
truder analysis is to some extent controversial and is not
addressed in this paper. Some researchers claim significant
differences between the actual (rotating screw in a stationary
barrel) and the simplified (Campbell et al., 1992; 1996). How-
ever, other researchers, reported negligible effects (Rauwen-
daal et al., 1998; Potente et al., 2006; Habla et al., 2013).
2 Problem Formulation and Solution Procedure
From the three functional zones (solids conveying, melting,
and metering) of an extruder, we focus our attention to the me-
tering zone close to the die, where the polymer is completely
molten. The screw terminology is explained in Fig. 1. Based
on practical design criteria, we assume an inside barrel diame-
ter of D = 100 mm, a channel depth H = 5 mm, clearance
by McMaster University on November 27, 2018. For personal use only.
d = 0.25 mm, flight width e = 10 mm, a helix angle h = 17.668
(pitch L = D = 100 mm, square pitched screw) and channel
width W = (pDtanh-e)cosh = 85.77 mm. We follow the usual
IPP 2018.33:662-668.
Fig. 1. Screw terminology schematic of the screw metering zone sec-
tion of 1D length
B)
A) C)
Intern. Polymer Processing XXXIII (2018) 5
mathematical flow analysis approach (Tadmor, 1966; Agur
and Vlachopoulos, 1982) of \unwrapping" the screw, assum-
ing the screw is stationary and the barrel moves at Vb =
0.31415 m/s (which corresponds to N = 60 min–1. To examine
the secondary flow details at the base of the screw flights a very
fine numerical grid is required, which implies a very large
number of unknowns. Consequently, the domain of computer
flow simulation must be carefully chosen to reduce the compu-
tational cost, which could easily become prohibitive, if a large
section were desired to be simulated. We will carry out flow
simulations for an unwrapped section equal to 1D as shown in
the schematic of Fig. 2A, which is sufficiently long for the ex-
amination of the flow features we are interested in. In the sche-
matic of Fig. 2B we show the cross-sectional shape of the melt
channel.
We use the open-source computational fluid dynamics pack-
age OpenFoam (Weller, 2015) which we have tested and used
for simulating several other problems involving Newtonian,
shear thinning and viscoelastic fluid models (Polychronopou-
los and Papathanasiou, 2014; 2015). We assume an incompres-
sible and isothermal fluid in steady, laminar and creeping flow
conditions (i. e. Re 5 1). Under these assumptions, the conser-
vation of momentum equation may be written as
0 ¼ rp þ r  s; ð1Þ
where p is the pressure and s the extra stress tensor. For the
case of purely viscous (inelastic) shear thinning fluids the vis-
cous stresses are given by the relation (Tanner, 2000; Vlacho-
poulos, 2016)
s ¼ gðjc_ jÞc;
_ ð2Þ
where gðjc_ jÞ corresponds to the non-Newtonian viscosity and
jc_ j is the magnitude of the rate-of-strain tensor
* *T
c_ ¼ ru þ ru , which is given by
rffiffiffiffiffiffiffiffi
1
jc_ j ¼ IIc_ ; ð3Þ
2
_ c)
where IIc_ = (c: _ is the second invariant of c.
_ We carry out
simulations for a Newtonian fluid and for a Generalized New-
Fig. 2. Schematic geometry (top view) of the
\unwrapped" screw channel (A), schematic
representation (B) of the channel cross-sec-
tional geometry (along the lines connecting
points A, B, C and D a progressive mesh cell
compression is applied) and computational
mesh detail near the pushing flight flank (C)
663
 N. D. Polychronopoulos, J. Vlachopoulos: Computer Flow Simulation of Moffatt Eddies
tonian Fluid (shear thinning) described with the Carreau model
given by
h iðn1Þ=2
g ¼ go 1 þ ðkjc_ jÞ2 ; ð4Þ
where go the zero-shear viscosity, k is a time constant and n the
power-law exponent.
Before proceeding with the 3D simulations we decided to
solve a 2D lid driven flow problem as a further test on the cap-
abilities of OpenFoam, and for the purpose of visualization of
the structure of the secondary flow field near the corners, for
Newtonian flow. For a cavity of width W = 100 mm, depth
H = 5 mm and lid velocity V = 0.31415 m/s we show two Mof-
fatt eddy regions at one of the corners as shown in Fig. 3. The
results are similar to those of numerous other publications on
2D lid driven flow appearing in the fluid mechanics literature.
To construct the geometric domain for 3D flow analysis, we
use the GMSH software (Geuzaine and Remacle, 2009). The
mesh generation is performed with both structured (regular)
and unstructured grids. The structured grid comprises of ortho-
gonal hexagonal cells and is used for discretization of the clear-
ance space (see Fig. 2B and C). In the leakage region, the grid
by McMaster University on November 27, 2018. For personal use only.
has 400, 100 and 10 cells in the x, y and z direction respec-
tively. The unstructured grid, used for the rest of the domain,
is a hybrid grid with non-orthogonal hexagonal and prismatic
cells (Fig. 2C) and a size of 2.1 million cells. In order to cap-
ture efficiently the flow characteristics near the corners of the
flights, the unstructured grid is made progressively finer. To
IPP 2018.33:662-668.
do so, we set the cell size near the origin of the coordinate sys-
tem equal to 0.2 mm (in both x and z directions) and apply a
progressive cell compression towards point B (or C) with the
smallest cell size being 4 · 10–3 mm (note that we divide line
AB into 500 segments). Similarly, we apply cell compression
from A to B (or D to C) by dividing the corresponding lines
664
into 150 segments. The cell size near A or D is chosen to be
4 · 10–2 mm. These cell sizes and their distribution were se-
lected after a series of repetitive simulations to assure grid-in-
dependent results.
We impose a fixed pressure gradient along the unwrapped
channel and we assume the usual no-slip condition at both the
screw surface (U = 0) and the barrel internal surface (U = Vb).
The governing equations are solved in an iterative manner fol-
lowed by the SIMPLE (Patankar and Spalding, 1972) pres-
sure-velocity correction loop (Ternik, 2010). For the solution
of the system of the linear equations we use a Preconditioned
Conjugate Gradient (PCG) scheme with Geometric agglomer-
ated Algebraic MultiGrid (GAMG) preconditioner for the pres-
sure and velocity (Saad, 2003; Ferziger and Perić, 2002). Both
tolerances for pressure and velocity are set to 10–7. To speed
up the simulations we run them in parallel mode on distributed
processors by geometric domain and associated fields decom-
position in a workstation platform comprising of 2 Octa-Core
CPU supplied with 64 Gb RAM. The average computation
time for the Newtonian cases was roughly 8 h, whereas for the
non-Newtonian approximately 12 h.
3 Results
The first case simulated is with the assumption of no pressure
gradient. The fluid is Newtonian having a viscosity of
833 Pa · s and the flight angles at screw root are 908. This
would correspond to a single screw extruder delivering an out-
put equal to the drag flow (Kramer and Steward, 2001) which,
neglecting leakage flow, is
1
_ D ¼ qpDNHðL  eÞcos2 h:
m ð5Þ
2
Fig. 3. 2D lid-driven cavity flow showing re-
presentative pathlines of the primary and sec-
ondary flow (Moffatt eddies) regions
Intern. Polymer Processing XXXIII (2018) 5
 N. D. Polychronopoulos, J. Vlachopoulos: Computer Flow Simulation of Moffatt Eddies

For assumed q = 1000 kg/m3, D = L = 100 mm, H = 5 mm,
N = 60 min–1 and h = 17.668 we get from Eq. 5 m_ D = 231 kg/h
and the average residence time (ART) is calculated from
ðpDÞ=cosh qpDHW
ART ¼ ¼ ; ð6Þ
Vavg _ D cosh
m
which gives ART ffi 2.2 s. From the computer flow simulation
results we choose judiciously a number of pathlines to show
the primary flow in front of the pushing flight and the second-
ary flow in the corner in Fig. 4. Fluid particles are dragged by
the moving top (barrel) wall, reach the flight flank, travel down
towards the bottom (screw core) and move towards the trailing
flight (not shown, due to the large width of the channel). A sec-
ondary flow occurs at the sharp corner like what is referred to
extensively in the fluid mechanics literature as Moffatt eddies
(Moffatt, 1964; Sousa, 2016) and to some extent similar to our
2D lid driven flow results of Fig. 3. A small increase of local
pressure is predicted due to the barrel wall dragging the fluid
against the screw flight. The pressure rise within the Moffatt
vortex is virtually identical to that at half the channel depth as
shown in Fig. 5.
For a better visual representation of the secondary flow we
by McMaster University on November 27, 2018. For personal use only.
tical and 0.3 mm from the bottom are shown in Fig. 7. They are
similar to those of Fig. 6, but more \compressed" because the
average flow rate is lower due to the adverse pressure gradient
(i. e. it corresponds to the existence of a die after the end of
the screw). The time for a particle to travel along the helical
pathline from start to finish is 1 349 s for the pushing flight
and 1 755 s for the trailing flight.
The third simulation study involves flow with an aiding
pressure gradient. Grooved feed extruders generate very high
pressures in the feed zone near the hopper (the length being
usually no more than 4D). Pressure levels can be very high.
Values up to 300 MPa have been reported (Rauwendaal,
2014). Such pressures are responsible for the high output rates
of grooved feed extruders (usually up to twice the drag flow
output). In the present simulation we chose Dp = 5.76 MPa for
the screw section under examination, which is commensurate
to pressure gradients for modern grooved feed extruders. The
pathlines (again originating at 0.12 mm from the vertical and
0.3 mm from the bottom) appear more \elongated" due to
higher average flow rate as shown in Fig. 8. The particle travel

decided to pick two points at the channel entrance, 0.12 mm

from the vertical and 0.3 mm from the bottom, ahead of the
pushing flight and behind the trailing flight as shown in
Fig. 6. It can be seen clearly, from the particle pathlines, that
Moffatt eddies are predicted both in front of the pushing flight
and behind the trailing flight. As expected, the two pathlines
IPP 2018.33:662-668.

shown are not identical in shape due to their different orienta-

tion to the primary fluid motion. The time for a particle to tra-
vel this section of the screw along the spiral shown in front of
the pushing flight is 483 s and the time for a fluid particle to
travel along the spiral behind the trailing flight is 512 s. These
large residence times are much larger that the average resi-
dence time and suggest that polymer particles following the he-
lical pattern of the Moffatt eddies at the corners are likely to be
subjected to various degradation mechanisms at the high tem-
perature of the extruder.
The second simulation study involves flow with an adverse
pressure gradient. We chose Dp = 1.73 MPa for the screw
section under examination, which would correspond to a
Fig. 5. Local pressure variation along a line near the pushing flight
reasonable value for single screw extruders (total length flank. Bottom curve: the line is located within the Moffatt vortex at a
L = 20*40 D) that usually can generate pressures of up to distance 0.2 mm from the screw bottom and 0.13 mm from the pushing
about 50 MPa at the die. The pathlines originating from the flight flank. Top curve: the line is located 2.5 mm from the screw bot-
previously selected starting positions of 0.12 mm from the ver- tom and 0.13 from the pushing flight flank

Fig. 4. Numerically computed pathlines for a

Newtonian fluid near the pushing flight re-
gion showing the primary and secondary flow
(Moffatt eddies) patterns

Intern. Polymer Processing XXXIII (2018) 5 665

 N. D. Polychronopoulos, J. Vlachopoulos: Computer Flow Simulation of Moffatt Eddies
times along the pushing and trailing flight spiraling pathlines
are 164 s and 184 s respectively.
The fourth simulation study involves only drag flow (i. e.
without any pressure gradient) of a Carreau fluid having
go = 104 Pa s, k = 1 s and n = 0.4. For drag flow under the con-
ditions of flow of Fig. 4 with N = 60 min–1 rotational speed, the
apparent Newtonian viscosity at the moving wall is 833 Pa s.
There is no qualitative difference in the primary or secondary
flows to those of the Newtonian simulation of Fig. 4 and
Fig. 6. For the chosen locations of the pathlines start of
0.12 mm from the vertical and 0.3 mm from the bottom shown
in Fig. 9, the travel times along the spirals in front of the push-
ing flight and behind the trailing one are 4 709 s and 7 990 s re-
spectively. These times are much larger than the corresponding
times for the Newtonian fluid, even though the apparent New-
by McMaster University on November 27, 2018. For personal use only.
A) B)
IPP 2018.33:662-668.
A) B)
A) B)
A) B)
666
tonian viscosity at the wall for the Carreau model is identical
to the viscosity used in the Newtonian simulations. The reason
is that near the corner the local shear rate is very small and the
local viscosity is very high (with the zero shear viscosity being
go = 104 Pa s).
All of the above simulations were carried out for sharp cor-
ners at the root of the screw flights. The Moffatt eddies are con-
fined within a short distance from the apex. Rounding off the
flight root would be expected to prevent the formation of sec-
ondary flows. Spalding et al. (2017) refer to SPI (undated)
guidelines which state that the recommended screw radius (R/
H in Fig. 10A) should not be less than 0.5. Spalding (2015)
suggests that R/H = 0.4 would be unsafe and R/H = 1.3 would
be safe (i. e. free from regions where degradation would occur
at the screw root). In Fig. 10B we show the flow field for a
Fig. 6. Numerically computed secondary
flow patterns (Moffatt eddies) for a Newto-
nian fluid at the (A) pushing flight flank and
(B) trailing flight flank. There is no pressure
gradient imposed along the screw length
Fig. 7. Numerically computed secondary
flow patterns (Moffatt eddies) for a Newto-
nian fluid at the (A) pushing flight flank and
(B) trailing flight flank. Imposed adverse
pressure gradient
Fig. 8. Numerically computed secondary
flow patterns (Moffatt eddies) for a Newto-
nian fluid at the (A) pushing flight flank and
(B) trailing flight flank. Case with aiding
pressure gradient
Fig. 9. Numerically computed secondary
flow patterns (Moffatt eddies) for a Carreau
fluid at the (A) pushing flight flank and (B)
trailing flight flank. Case with no pressure
gradient
Intern. Polymer Processing XXXIII (2018) 5
 N. D. Polychronopoulos, J. Vlachopoulos: Computer Flow Simulation of Moffatt Eddies
A) B)
screw channel having R/H = 0.4. There is no secondary flow
despite Spalding and co-workers recommendations to the con-
trary, based on practical experience.
4 Discussion
The computer simulations show that besides the primary flow
by McMaster University on November 27, 2018. For personal use only.
in the screw channel, there is a secondary flow in front of the
pushing flight or behind the trailing flight, akin to Moffatt ed-
dies, which have been extensively studied in the field of fluid
mechanics, both at low and high Reynolds number flows. The
formation of the such secondary flows occurs when the screw
flight roots are sharp (90 degrees with the screw core, in our
IPP 2018.33:662-668.
simulations). The numerical determination of Moffatt eddies
in the 2D lid driven cavity flow is fairly straightforward. How-
ever, the determination of the secondary flow in front of the
pushing flight and behind the trailing flight in a screw channel
requires a very fine grid and significant amount of computer
time, for carrying out numerical simulations. Fluid particles
traveling along the helical pathlines of the secondary flow
(Moffatt eddies) have residence times of more than two orders
of magnitude larger than the average residence time. Such,
long residence times result in degradation as it has been
pointed out by Spalding and co-workers (Spalding et al.,
1999; Spalding and Gou, 2015; Spalding, 2015; Spalding et al.,
2015). Degraded material occasionally gets cut off from the
screw base and produces black specks or other forms of quality
deterioration in extruded films. According to the present simu-
lations, secondary flow eddies exist in the absence or presence
of a pressure gradient. An adverse pressure gradient gave a
more \compressed" secondary flow pathline, while an aiding
pressure gradient an \elongated" one. The shear-thinning fluid
gave similar results to those of the Newtonian fluid.
Rounding off the screw root with a radius of curvature R/
H = 0.4 did not produce any secondary flow eddies. Also, the
results of the previous simulations could easily be subjected to
post-processing to determine the approximate size of the Mof-
fatt eddies. By selecting starting points for pathlines along a
line dividing the 908 corner in two equal angles (of 458 each)
and progressively away from the apex, we concluded that
rounding off the flight roots to radii larger than about R/
H = 0.2, we will not obtain secondary flows. This result is for
significantly lower radius than the \recommended" by SPI,
R/H = 0.5. However, our simulations were carried out for a
Newtonian and a shear-thinning (Carreau) fluid and for the
Intern. Polymer Processing XXXIII (2018) 5
Fig. 10. Cross-section geometry of the
rounded-off screw root in the pushing flight
flank (A) and representative pathlines for root
radius R/H = 0.4 (B)
geometry given in Fig. 2. Viscoelastic simulations, by analogy
to the entrance flow problem, would be expected to give larger
Moffatt eddies. Also it is known that when the channel aspect
ratio increases the size of the Moffatt eddies increase (Sousa,
2016). This means that deeper extruder channels would require
a higher R/H ratio. The question of screw flight root radius is
broader than just the formation of Moffatt eddies. For some
temperature sensitive materials degradation might also occur
in regions of relatively slow flow near a screw flight surface
without necessarily being caught in a Moffatt eddy. So the
SPI recommendation of screw root radius R/H = 0.5, seems to
be reasonable.
5 Concluding Remarks
It is predicted that secondary flows (Moffatt eddies) are formed
at the screw root in front of the pushing flight or behind the
trailing flight of a single screw extruder, if the angle is sharp
(90 degrees with the screw core) in the metering zone. Due to
extremely large times required for fluid particles to travel
along the helical Moffatt eddy pathlines degradation is likely.
The computer simulations are in good agreement with experi-
mental evidence on the formation of a thin carbonaceous film
in screw root regions. Screw flights roots of relatively large
radii (R/H) do not allow the formation of secondary flows.
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Intern. Polymer Processing
XXXIII (2018) 5; page 662 – 668
ª Carl Hanser Verlag GmbH & Co. KG
ISSN 0930-777X
Intern. Polymer Processing XXXIII (2018) 5