Numerical Simulation and Optimization of Novel and Efficient Screw Structures for Spinnable Pitch

In recent years, there has been a growing shift toward the use of screw extruders in the pitch modification process. To further improve the mixing efficiency of twin-screw extruders in pitch processing, this study focuses on redesigning the mixing elements of a co-rotating twin-screw extruder. By integrating the conventional kneading block assembly with PTA technology, three innovative screw mixing elements were developed. In this study, numerical simulations were performed using the finite element method (FEM) in the ANSYS Polyflow 2022 R1 software. The dynamic mesh technique was employed to model the screw rotation. The mixing performance of these novel screw elements was then evaluated in terms of distribution, mixing, and shear effects by utilizing the Particle Tracking Analy sis (PTA) technique within the Polyflow statistical module. The results demonstrate that the configuration and structural design of the mixing screw elements significantly influence the mixing effectiveness of spinnable pitch. Among the tested configurations, the slotted thread mixing element with six slots and a 30° slot angle (Model 2) was identified as the optimal design, exhibiting markedly superior mixing performance compared to the traditional kneading block (Model 4).