NEWEX kick-off meeting 27 th January, 2017 Antnio Gaspar-Cunha - PDF document

16-02-2017 NEWEX kick-off meeting 27 th January, 2017 António Gaspar-Cunha Institute of Polymers and Composites, Department of Polymer Engineering, University of Minho Guimarães, Portugal Location Department of Polymer Engineering NEWEX University of Minho 1

16-02-2017 City of Guimarães Department of Polymer Engineering NEWEX University of Minho City of Guimarães HISTORIC CITY CENTRE – Intramural Area (Classified UNESCO World Heritage Site) Department of Polymer Engineering NEWEX University of Minho 2

16-02-2017 University of Minho: Campus of Azurém Department of Polymer Engineering NEWEX University of Minho Facilities at University of Minho Department of Polymer Engineering NEWEX University of Minho 3

16-02-2017 Equipment at IPC Single-screw Leistritz extruder Twin-screw Leistritz extruder • Blow-film extruder Haake Reomix OS600 (Thermo Scientific Inc.) • NIR spectrometer Matrix-F (Bruker Opts.) • SALS system (prototype) • TA instruments AGR2 • Capillary rheometer Rosand • DMA Triton • DSC – SC Diamond Pyris • TGA – TA Q500 • FTIR Jasco 4100 with accessory ATR • Micro-injection Boy 12 and Babyplast • Micro-extruder twin screw Department of Polymer Engineering NEWEX University of Minho • Extrusion modelling • Optimization methodology Department of Polymer Engineering NEWEX University of Minho 4

16-02-2017 Modelling: plasticating phenomena Physical phenomena inside the extruder i) Hopper Heating bands ii) v) vi) iii) iv) Die Transversal cuts Melting Pumping Solids Delay conveying i) Solids conveying in the hopper – conveying due to gravity; ii) Solids conveying in the screw – conveying due to friction ; iii) Delay – conveying of solids (partially) surrounded by a melt film ; iv) Melting – accordingly with a specific melting mechanism; v) Pumping ; vi) Melt flow trough the die . Department of Polymer Engineering NEWEX University of Minho Modelling: software Melt conveying Solids conveying conventional screw q b V Δ z Barrel b y T b q f q f Flight Flight H H x Screw W q s T s T(y) Delay ( 1 ) Melting V b V b T b T C C b Delay ( 2 ) H H D B A A E D V b x T s T s T(y) W B T(y) W B T b C V sz H B A D B E T s W B T(y) V b Melting Department of Polymer Engineering NEWEX University of Minho 5

16-02-2017 Modelling: software V b Melting Delay (2) V b T b C Melt conveying ( Barrier ) T b Delay (1) H B A D C V bx H Vb Vb H B E T b A D T(y) x B Tb E T s T(y) C T s H G B H A T(y) barrier screw T b T(y) Ts Delay (2) ( Barrier ) Melting ( Barrier ) Solids conveying V V b b T b T b qb Barrel C C F F y qf qf H G H B A D G B A D B D W B E Flight T(y) E Flight T(y) Ts T s x W Screw qs Solids conveying ( Barrier ) Melt conveying V b Delay (1) ( Barrier ) V b V T b b T H b F C H G H A T(y) T b T(y) T s Department of Polymer Engineering NEWEX University of Minho Modelling: software PROCESS PARAMETERS : Geometry Polymer proprieties Processing conditions PERFORMANCE MEASURES: Output Power consumption I- Solids conveying ( hopper ) Melt temperature II- Solids conveying ( screw ) Temperature homogeneity III- Delay Mixing degree IV- Melting Length for melting V- Pumping Capacity to generate pressure VI- Die … Department of Polymer Engineering NEWEX University of Minho 6

16-02-2017 Modelling: results for a Maillefer screw Screw 1: L1 = 10.4D Screw 2: L1 = 3.6D MAILLEFER L2 = 7.0D L2 = 7.0D L3 = 8.6D L3 = 15.4D 1.0 1.0 0.8 0.8 X/W 0.6 X/W 0.6 0.4 0.4 0.2 0.2 0.0 0.0 0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0 L(m) L(m) 80 WATS x 10 80 WATS x 10 60 60 Pmax (MPa) Q x 0.2 (kg/h) Q x 0.2 (kg/h) Pmax (MPa) 40 40 20 20 0 0 Power x 100 (W) Zt x 0.02 (m) Power x 100 (W) Zt x 0.02 (m) Tmelt x 10 (ºC) Tmelt x 10 (ºC) 20rpm 40rpm 60rpm 80rpm 100rpm W s W m Department of Polymer Engineering NEWEX University of Minho Optimization Optimization RESULTS Algorithm Evaluation/ new (better) USER INTERFACE solutions Extruder/die Differences in Performance response Modelling Objective Package Function Department of Polymer Engineering NEWEX University of Minho 7

16-02-2017 Optimization: multi-objective evolutionary algorithm MO Problem Characteristics Numerical/modelling routines Evaluation of solutions Structural mechanics Design Decision Making Fluid dynamics MOEA Aerodynamics Robustness Comfort assessment … Hybridization Objectives reduction Inverse Decision Making Methodology Framework Interface DM1 DM2 Empirical knowledge Selection of the desired solutions No Yes Good END Solution(s)? Department of Polymer Engineering NEWEX University of Minho References Application in Polymer Extrusion https://www.novapublishers.com/catalog/product_info.php?products_id=20015 Department of Polymer Engineering NEWEX University of Minho 8