A comprehensive 3D analysis of polymer flow through a conical spiral extrusion die

Several restrictions which are related to extruder machinery and nature of process material exist in the design of plastic extrusion dies. To this respect, it is very important to consider design criteria and limitations in order to operate extrusion dies at desired production rate and temperature. In the current study, flow field characteristics through a conical spiral mandrel die are analysed in detail by 3D Computational Fluid Dynamics (CFD) simulations. The effects of operating conditions such as production rate and temperature on pressure drop through the spiral mandrel die and the occurence of melt fracture are investigated. The temperature dependent viscosity versus shear rate data for grade QB79P (CarmelTech) polypropylene (PP) melt under study are measured by use of rotational and capillary rheometers. Stress terms in the momentum equations are modeled by Generalized Newtonian Fluid (GNF) Model. For this, Bird-Carreau Model is employed as the viscosity model for the polymer melt. 3D CFD analyses provide comprehensive data and understanding with regard to flow behaviour through complex extrusion dies.