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10000 0.6 Pa s n
250oC
2300 J/(kg oC) and heat of fusion 200,000 J/kg. The polymer pellets enter
at 20oC and the product exits at 250 oC into a 8mm diameter (R=4mm)
and 480mm long die channel. The screw rotates at N=60RPM.
(a) Calculate the drag flow output.
(b) Output by taking into consideration the head pressure generated by
the die.
(c) Calculate the power for the motor assuming that it produces 100% of
the energy
needed to raise the melt temperature to 250 oC, to melt and pump the
polymer.
(d) Calculate the torque.
RECALL:
Po F V
Power
F Po / V
( force x velocity )
To F R
Torque
To
Po
P
P
R o R o
V
2NR
2
Then after these calculations I want you to go backwards. That is, you
To F R
are going to start from calculation of torque,
, where
F A
Po F V o A V
(wall shear stress) x area and then calculate the power
To A R H .
for the torque equation calculation is just (R-H), i.e.
(e) Calculate the power and torque from shear stress calculations
(f) Comment on the differences in the above calculations and what should
have to be
done to minimize the differences.
Solution:
(a) To calculate the drag flow output of the extruder we have
1
QD 2 D 2 HN sin cos
2
(1)
QD 1.42 D 2 HN
(2)
and since the mass flow output is
m D QD
(3)
by substitution of equation (3) to equation (2) we have
m D 1.42 D 2 HN
(4)
2
m D 1.42 780
kg
60 1
kg m 2 m
3 2
2
3
100
10
m
10
m
0
.
05538
D
60
m3
m3 s
m D 0.05538
kg
kg
m D 199.37
s
hr
(b) To calculate the operating point of the extruder/die we must plot the
operating lines for the extruder and the die.
The calculation of the operating line of the extruder needs only two set
P, m D
of points
where the pressure is zero as the die is absent, and the second point is for
the maximum possible pressure when the die is completely closed. To
calculate the maximum possible pressure the following formula is used
Pmax
6 D L N
2 tan
(5)
n 1
V
m
n 1
DN
m
60 H
n 1
(6)
Pmax
6 D L N
DN
2
tan
60 H
n 1
(7)
Pmax
60 1
s
1
1 3.1415 0.1m 60 s
60
10000
Pa
2
3
2
o
60 5 10 m
m tan 17.66
5 10
3
0. 6
n
Q
3n 1
1 P
2m L
1
n
Rn
(8)
Now we calculate the volume flow rate of the melt for six values of
pressure which are at 0MPa, 10MPa, 20MPa, 30MPa, 40MPa and 50MPa. Of
course, for zero pressure drop from equation (8) we can see that the
volume flow rate is also zero. Calculating the flow for the pressure drop of
10MPa we have
10 10 6 Pa
0 .4
1
Q 3.415
1
3 0.4 1 2 10000 Pa s 0.480m
Q 1.29 10 5
m3
m3
Q 4.6 10 3
s
hr
1
0. 4
m 3.6
or
0.004m 0.4 3
kg
hr
Working the same way as above for the other values of the pressure drop
for the die we have the following table and after that the operating lines
4
for the extruder and the die are plotted. Also, from the figure below we
m
can see that the approximate values for the operating point is
10
3.6
20
20.5
30
56.6
40
116.4
50
203.1
Table 1.
Operating Lines
250
200
150
100
50
0
0
50
Pressure (Mpa)
Figure 1.
(c) The power supplied by the motor is spent for raising the temperature
from Tin to Tout, melting the polymer and pumping the polymer. To calculate
the amount of the power the following formula is used
Po Q C p To ut Tin Q H f P Q
(9)
Po m D Q C p To ut Tin m D H f P
Po
m D
199.37 kg
J
199.37 kg
J
o
2300 o 250 20 C
2 105
3600 hr
kg C
3600 hr
kg
45 10 6 MPa
199.37 m 3
3600 780 hr
58.38
1
83.4 HP
0.70
motor.
To F R To
Po
R To
V
To
PO
D 2H
N
60
D 2 H To
PO
N
60
43567W
To 13874 N m
60 1
3.1415 s
60
Po m w Area D 2 H
n
D 2H N
H
60
Po m
N
60
D 2 H Ls D 2 H
N
60
(10)
Ls should be the length along the helix (polymer dragged along helical
channel) so
Ls
L
26 D
26 0.1m
Ls
Ls
Ls 8.58m
sin
sin 17.65
0.30
(11)
0.4
60
60
Po 34412W Po 34.4kW
To calculate now the torque we have
Po
P
34412
Po
D 2 H To o To
To 10959 N m
R To
N
N
60
V
D 2H
3.1415
60
60
60
To
(f) Actually the previous estimate is close to the estimate from heat
transfer considerations (43567 W). Of course it all depends on the stress
calculations. A sketch of the screw is shown in the following figure.
Figure 2.
F V
over the
fluid volume. However, in the transition and feed zones we have a mixture
of solids and melt and it is virtually impossible to arrive at good estimates
of the stress developed.
In the present calculation we assumed that the stress generated by the
motor is the same throughout the screw and we calculate it at a distance
of H = 0.005m from the barrel wall at an assumed temperature of 250 oC
throughout.
Comments: The real extruder has a compression section as shown in the
figure below (Figure 3). In the compression section there would be some
pressure generation and the pressure profile would look like the one
showed in Figure 4.
Figure 3.
10
Figure 4.
Figure 5.
11
12