Comparison between 1D and 3D Approaches for Twin-Screw Extrusion Simulation

In this paper, numerical simulations of flows in a co-rotating intermeshing twin-screw extruder are performed using a previously presented 3D finite elements model. Some numerical improvements recently introduced are presented. The computations are performed for several processing conditions and screw arrangements. Values of specific energy, pressure and filled length are compared to the results issuing from the 1D Ludovic software in order to compare both approaches. The 3D simulation method is found to be more accurate to describe the effect of varying staggering angle and thickness of kneading discs. On the other hand, 1D model provides very satisfactory results for flows in screw elements.