Introduction of an Euler–Lagrange framework for a single screw extruder based on the extended discrete element method (XDEM)

Abstract This article presents a novel Euler–Lagrange modelling framework for the dynamic analysis of single screw extruders, commonly used in polymer and food processing industries. Traditional modeling approaches often rely on empirical correlations and steady-state assumptions, limiting their accuracy in capturing transient behaviors and complex interactions within the extruder. The proposed framework leverages the principles of Euler–Lagrangian coupling mechanisms to systematically derive the governing equations for both particles and fluids. By treating the extruder as a system with coupled mechanical and thermal domains, this approach enables a more accurate and physically consistent representation of its dynamic behavior. Simulation results demonstrate the model’s capability to predict transient responses and highlight its potential for use in control design, process optimization, and fault detection. This work lays the foundation for a unified and extensible modelling strategy for advanced extrusion systems.