Screw Configuration Analysis Algorithm and Energy Correction Model for Polypropylene Melt Behavior in Twin‐Screw Extrusion

ABSTRACT Twin‐screw extruders (TSEs) are widely applied in polymer processing, where the screw configuration critically influences melt flow behavior and product performance. Existing analyses of these effects are mostly based on the assumption of fully filled flow, which deviates from real processing conditions and limits accurate evaluation of mixing efficiency and energy dissipation characteristics. To address this limitation, a screw configuration analysis algorithm based on dynamic fill degree is developed to enable real‐time evaluation of multi‐parameter screw characteristics, material fill degree, and rheological behavior. Experimental validation on an industrial Φ30 mm extruder processing polypropylene demonstrates high accuracy in characterizing screw performance and material distribution. By integrating the experimental data, an energy correction model is further established, reducing the prediction error to within ± 5%. This study provides a novel tool for precise control and energy assessment of twin‐screw extrusion processes, facilitating reduced energy waste and supporting industrial energy conservation.