Advanced Materials Research Vol 997 (2014) pp 605-609 Submitted: 2014-05-08

© (2014) Trans Tech Publications, Switzerland Accepted: 2014-06-04

doi:10.4028/www.scientific.net/AMR.997.605 Online: 2014-08-11

Security Analysis on Single-screw Extrusion Process of Solid Propellant

by Numerical Simulation
Zhongqi HE1, a, Ke ZHOU1,b , Shupan YIN 1,c
1
School of Chemical Engineering, Nanjing University of Science and Technology, Nanjing, 210094,
China
a
hzq555@163.com (corresponding author), b411607149@qq.com, cpyshu@126.com

Keywords: Single-screw Extrusion Process; Solid Propellant; Security Analysis; CFD; POLYFLOW.

Abstract. Solid propellants are flammable, explosive, which maybe initiated unexpectedly under
specific excitation conditions through high-speed screwing. Though single-screw extrusion process
for solid propellant occurred a large proportion accidents, the rheological parameters of the propellant
material were difficult to get yet, which affects the process safety greatly. In this paper, the CFD
software, POLYFLOW, and a numerical simulation method were adopted to investigate the
rheological parameters in single-screw extrusion process of solid propellant. By analyzing the
rheological state of a solid propellant in the screw extrusion process, the applicable numerical model
was established with a substitute material for the propellant. As a result, distributions of key
parameters, such as material temperature, pressure, viscosity, were obtained. The simulation shows
that the material has relatively higher pressure, temperature and smaller viscosity at the screw edge,
where solid propellant components were mixing and plasticizing severely, also where needs pay
much attention to for safety reasons.

Introduction
Solid propellant, as a major Energetic Materials in China, is widely loaded in rockets, missiles. While
propellants burn themselves steadily in combustion chamber, large amounts of energy and
high-temperature gas products are released, rapid propulsion for rockets and missiles are achieved.
With the rapid development of China's aerospace industry in recent years, the scale of production of
propellant expands greatly. On the other hand, the safety of solid propellant processing is much
concerned. In many military enterprises, single-screw extrusion is one of the most important
processes for solid propellant plasticization and molding. As a high energy density materials, solid
propellant are flammable, explosive, which maybe initiated unexpectedly under specific excitation
conditions through high-speed screwing. Table 1 shows a number of accidents occurred in different
steps during solid propellant processing in last eighties. Both Rolling step and Stretching step have a
higher frequency in statistics, and caused much more loss than other steps during solid propellant
processing. Also the two steps in fact are single-screw extrusion involved, which deserve much
attention.
Table 1 Accident occurred in different steps during solid propellant processing [1]
Rolling Stretching
Driving
Step Blending Slurry (single-screw Drying Thermostatic (single-screw
water
extrusion) extrusion)
Accidents 12 7 23 56 23 2 86
Direct economic
loss
（ ten thousand
43.15 2.63 3.00 23.43 20.50 0.22 89.40
yuan, RMB ）
Propellant extrusion process is a collection of components conveying, melting, conveying and mixing.
Unlike solid propellant, much more research about single-screw extrusion processing focus on
plastics modeling. K.WilczyÄski[2] emphasized the temperature and pressure curves on several
plastics feeding step. Y. Jaluria[3] studied Solid Transport Model is screw with different operating

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606 Frontiers of Chemical Engineering, Metallurgical Engineering and Materials III

conditions, screw geometric characteristics and friction from groove. Based on Single-Screw
Extrusion Model, M. R. Thompson[4] studied numerical simulation. Lin ZHANG[5] also simulated
solid transport in single-screw extrusion under vibration force field using the discrete element method.
However, current research on the process of the screw extrusion is quite inadequate, especially on the
rheological parameters of the propellant material, which affects the process safety greatly. Due to
difficulties in measurement of solid propellant inside screw, numerical calculation of solid propellant
flow temperature, pressure will be great helpful for safety assessment of this process. In this paper,
the CFD software, POLYFLOW, and the numerical simulation method were adopted to investigate
the rheological parameters of material of the screw extrusion process，which provides a scientific and
effective reference to the technological process control and safety analysis.

Computational Model
Basic principles. Based on solid propellant characteristics and single-screw extrusion process, here
are basic assumptions:
(1) As a generalized Newtonian viscous fluid, object solid propellant meets pseudoplastic fluid
characteristics.
(2) Target fluid is a laminar flow in the screw. Because screw speed is relatively small, also the
Reynolds number.
(3) Only the fluid viscous force is concerned, as inertial force and gravity here are comparatively
small.
(4) In line with the actual conditions, the fluid is incompressible and very viscous in the screw.
(5) Substitute Material for object solid propellant is recommended, there will be no chemical
reaction or change in density.
Now equations of continuity, momentum, energy conservation, as well as material flow model in
the screw are established[6]. In addition, the material constitutive equation is given by Bird-Carreau
mode:
 n −1
 −b T −T 
 
2 2
η = η∞ + (η0 −η∞ ) 1 + ( λγ
)   e  0  （1）
   
 
η
where, is the current viscosity; η 0 is the starting shear viscosity; η ∞ is the infinite shear
viscosity; n is the Non-Newtonian index; λ is the relaxation time; is the shear rate, determined by
the rotational speed; T0 is the inflow temperature, 330K; T is the current temperature.

Table 2 Rheological parameters of Substitute Material for solid propellant

parameters value Parameters value

Density ρ[kg ﹒m ]
-3
1.78×103 Specific heat capacity [J
﹒
/(kg K)]
3500

Starting shear viscosity η [ Pa﹒s]

0 2.5×107 Non-Newtonian index n 0.38
Infinite shear viscosity η ∞ [ Pa﹒ s]
Temperature coefficient of
0 2
sensitivity b
Heat transfer coefficient k[ W﹒ m ﹒ K ]
-1 -1
0.35 Relaxation time λ [s] 4.48

Computational model. Geometric parameters about the traget single-screw is given by Fig. 1 and
Table 3.
 Advanced Materials Research Vol. 997 607

Fig. 1 Geometric parameters about the traget single-screw [7]

； ； ；
D—outer diameter d—root diameter t—thread pitch w—groove width e—edge width ；
； ；
h—groove depth φ—groove angle L—screw length δ—gap ；
Table 3 Parameters of single-screw in numerical simulation
Geometric Single-screw Gap to sleeve
parameters d D L e t H δ
Value[mm] 80-90 100 500 6 83.3 5-10 5

(a) flow channel (b) single screw

Fig. 2 Schematic diagram of flow channel and single screw

Results and Discussion

Fig. 3 shows pressure cloud result in cross section of solid propellant flow, which fluid pressure
difference is 8Mpa, screw rotate speed is 10r/min, inlet fluid temperature is 60 ℃, heating water
temperature is 80 ℃ inside screw, cylinder wall temperature is 70 ℃. Plots show that along the radial
direction, high pressure appears near the screw where the flow is moving forward. But on the
dragging surface high pressure near the cylinder is relatively higher. We can infer that the propellant
fluid goes to screw wall and converge there while moving forward, and gathers to cylinder at the end.

(a) Pressure cloud at Y=0 (b) Pressure cloud at Z=0.25m

Fig. 3 Pressure cloud in Cross section of fluid, screw rotate speed 10r/min

Table 4 shows the maximum pressure value and the position of the flow by different screw speeds,
3r/min, 5r/min, 7r / min, 10r/min, 12r/min, 15r/min respectively. the speed was under maximum
pressure value x = 0.051mm and appear at the position as shown in Table 4.
608 Frontiers of Chemical Engineering, Metallurgical Engineering and Materials III

Table 4 The maximum pressure value and location at X-axis 0.51mm by different speed
Rotation Speed
3 5 7 10 12 15
[r/min]
Z-axis position [m] 0.339 0.336 0.215 0.214 0.213 0.174
Max Pressure[Mpa] 11.93 13.55 15.28 18.14 19.94 22.61

Max Pressure [Mpa]

Rotation Speed[r/min]

Fig. 4 Maximum pressure of the solid propellant fluid increases with screw rotate speed

(a) Sectional temperature contours atY=0 (b) Sectional temperature contours at Z=0.05mm

(c) Sectional temperature contours at Z=0.2mm (d) Sectional temperature contours at Z=0.35mm
Fig. 5 Sectional temperature contours

Four flow temperature profiles along the z-axis direction at x = 0.047m; x = 0.049m; x =
0.051m; x = 0.053m, while keep Y = 0, are reflected in Figure 5. These curves show that where the
propellant flow is near the screw, it gets higher temperature. While the fluid goes near the sleeve, the
temperature gets relatively low. Because there is a large area of the screw and the propellant flow in
contact with, heat transfer can be very good. Also surrounding by cooling water outside, the sleeve
gets lower temperature.
 Advanced Materials Research Vol. 997 609

Fig. 6 Temperature curves along z-axis at different x-axis position

From Fig. 6 where any the temperature curve goes down, we found it occurs on screw arris as the
dragging surface, where an enhanced intermolecular friction produced due to extra external force on
the propellant fluid. The extrusion fluid temperature gets another climax where material gathers most.
Again due to shearing action of the screw, propellant fluid turns lower viscous, causing less
intermolecular friction and also lower temperature. Therefore, in single-screw extrusion process,
temperature and pressure of the propellant fluid both continuously wave up and down. Overall, the
fluid temperature goes up to around 358K from 333K at the inlet. The maximum material temperature
increases by 26K, the screw temperature goes up 5K as well, from viscous heat.

Conclusion
(1) In single-screw extrusion process, computational results show that temperature and pressure of
the solid propellant fluid increase from the inlet, then continuously keep waving up and down.
(2) Maximum pressure of the solid propellant fluid almost increases linearly with rotate speed of
the screw. Also raised speed can cause a higher fluid temperature during Rolling step and Stretching
step in solid propellant processing. To avoid fire or explosion accidents in the process, safety
operation parameters must be set for corresponding solid propellant.

References
[1] Guangming QIN, Zhaoxian BO. Solid propellant charge design[M]. Beijing: National Defense
Industry Press, 2013. (in Chinese)
[2] K. WilczyÄski. Single-screw Extrusion Model for Plasticating Extrusion [J]. Polymer-Plastics
Technology and Engineering, 1999(4):581-608.
[3] Y. Jaluria. Modeling and Simulation of the Solids Conveying and Unfilled Regions in Polymer
Extrusion [J]. Journal of Reinforced Plastics and Composites, 1999, 18(1):15-26.
[4] M. R. Thompson. Discrete Particle Simulation of Solid Compaction and conveying in A
Single-Screw Extruder[J]. Polymer Engineering and Science, 2008, 48(1):62-73.
[5] Lin ZHANG, Jinping QU, Jianbo LI. Simulation on solid transport in Single-screw extruder in
vibrating force field with discrete element method [J]. China Mechanical Engineering, 2006, 17
(22), 2406-2410. (in Chinese)
[6] Yaopeng LIU. Technology of explosive manufacturing[M]. Beijing: Beijing Institute of
Technology Press, 2009. (in Chinese)
Frontiers of Chemical Engineering, Metallurgical Engineering and Materials III
10.4028/www.scientific.net/AMR.997

Security Analysis on Single-Screw Extrusion Process of Solid Propellant by Numerical Simulation

10.4028/www.scientific.net/AMR.997.605

DOI References
[4] M. R. Thompson. Discrete Particle Simulation of Solid Compaction and conveying in A Single-Screw
Extruder[J]. Polymer Engineering and Science, 2008, 48(1): 62-73.
http://dx.doi.org/10.1002/pen.20845