Abstract: Three dimensional mixing flow fields of a composite melt around the metering zone (the length was 440 mm) of 4 screw assemblies were simulated by utilizing polymer flow package Polyflow. The composite was highly filled with aluminum powder. Based on the analysis of the flow field，especially the shear rate, shear stress, and axial velocity distribution, general distribution characteristics and mixing capability were studied. The performance of screw elements was compared. The results of holistic simulation, which were verified with experiments, showed that the screw configuration with negative elements and kneading disks had higher dispersive and distributive mixing capability for aluminum powder filled materials.

Key words: aluminum powder, metering zone simulation, mixing goodness, configuration optimization