Verifying the Melting Behavior in Single-Screw Plasticization Units Using a Novel Simulation Model and Experimental Method

We report on the development of a novel non-invasive ultrasonic measurement system for determining the melting behavior in a single-screw plasticization unit (35/22D) and on a modified drag-induced melt removal model that builds upon that by Tadmor and Gogos (2006). The solid bed to melt pool ratio is quantified using a non-invasive ultrasonic system based on reflection measurements. Automated analysis of the reflected pulses – measured at different axial positions along the barrel – allows the melting process to be monitored online. Our analysis of the delay section incorporates viscous dissipation into Tadmor's drag-induced melt removal model. We link temperature profile and melt film thickness via differential equations and consider viscous dissipation. By segmenting the delay section in the axial direction, the temperature dependency of the thermo-physical material properties is also considered. Using the melting behavior measured for different materials, we verified the mathematical model. Additionally, the effect of reduced screw length on the plasticization process, important for the injection molding process, was investigated.