Non-Newtonian Extrusion & Mixing Simulation

Task 1: Extrusion Simulation of Non-Newtonian Paste Using Auger Screw in CFD

Objective: Model and analyze the extrusion of a paste-like, non-Newtonian material through an auger screw system.




Task 2: Mixing Simulation of Two Non-Newtonian Fluids in Auger Screw Extrusion

Objective: Simulate and evaluate the mixing efficiency of two non-Newtonian fluids fed through an auger screw extruder.

Requirements:

Use same/similar auger screw geometry as Task 1.

Define two inlet streams with different fluid properties (e.g., viscosity, concentration, or tracer species).

Track mixing quality using species transport or passive scalar method.

Analyze how screw design, rotation speed, and inlet flow ratio influence mixing efficiency.

Output: mixing index, concentration distribution, velocity field, pressure drop.

Deliverables:

Geometry + mesh files.

Simulation setup files.

Post-processed data (concentration contour plots, mixing efficiency metrics, animations).


Requirements:

Implement non-Newtonian rheological model (Bingham Plastic / Herschel–Bulkley).

Create auger screw geometry (barrel, screw, nozzle).

Apply rotational motion to the screw, with material fed from inlet and discharged at outlet.

Simulate velocity field, pressure distribution, shear rate, and mass flow rate at the nozzle.

Deliverables:

Geometry + mesh files.

Solver setup (boundary conditions, rheology implementation).

Post-processed results (plots, animations, numerical values).

Preferred software: ANSYS Fluent / COMSOL