SOFTWARE TOOLS FOR IMPROVED

PRODUCTIVITY

Presented by

Adam Dreiblatt
Director of Process Technology
Copyright 2014, Century Extrusion, all rights reserved

Webinar outline

WinTXU Screw Configuration Management software

WinTXS Simulation Software

PolyTech developed the WinTXU Screw Configuration

Manager product in 2004 as the future Windows interface for
TXS Twin-Screw Extruder Simulation Software. In the
meantime, WinTXU has been highly successful in the
marketplace as a standalone screw design software tool while
further developing this interface for WinTXS
Developed by PolyTech
Distributed by Century Extrusion

WinTXU Screw Design Software

Design elements to align with barrel openings

Document configuration for archiving, reporting

WinTXU Twin-Screw Extruder Configuration Manager

Limited availability of OEM screw design software

Single platform to design screw configurations for multiple OEMs
Machine database designed for each customer
Component library loaded with each machine model

WinTXU Twin-Screw Extruder Configuration Manager

Cost of one screw design error
Kneading block mistakenly positioned within vent port
Error occurs since graphic image not available
Lost production to identify error (estimate @$350/hr)

Downtime to reconfigure screw (estimate 4 hours @$350/hr)

Cost of materials (scrap produced to identify error)

WinTXU can pay for itself if one error is avoided !

Current WinTXU extruder database (>120 models):

Coperion (ZSK, ZSK-SC, MC, MC+, MC18, STS)

Century (CXE, CX and APEX series)
Berstorff (ZE, ZE-A, UT, UTX)
Leistritz (ZSE, includes HP, MAXX series)
Theysohn (TSK)
Prism (TSE, KX series)
Buhler
Ruiya (TSE, RXT series)
Clextral (BC and Evolum series)
Sino-Alloy (PSM)
Farrel (FTX)
Baker Perkins (MP series)
JSW
Any co-rotating twin-screw
Toshiba
extruder can be added to
the WinTXU database!

WinTXU system requirements

IBM-PC (or compatible personal computer)

150MHz processor speed (minimum)
16MB RAM (minimum)
32MB free hard disk space
SVGA color monitor (256 color minimum)
Mouse (or compatible pointing device)
CD-ROM drive (or network connection)
USB port
Microsoft Windows 95, 98, Me, 2000, XP, Vista, 7
Adobe Acrobat Reader 5 (or later version)

Step 1 select machine model from database

Step 2 - select pre-defined L/D or

specify number of barrels to create
custom shaft length

Step 3 assemble barrel configuration.

Double-click on barrel name or dragand-drop icon from above

Step 4 assemble screw

configuration. Double-click on
element name or drag-and-drop
icon from above

Inventory feature applies to

elements and barrels enter
current stock for each component
in the table to the left. As you build
a new screw design, WinTXU
keeps track of remaining inventory

Zoom in/out to see

complete configuration or
smaller portion

Cumulative barrel,
shaft and screw
lengths displayed
here

Change units used for

displaying operating
conditions

Change color coding

of elements

Input all operating

conditions to be
stored, printed with
screw

Input all details for die,

breaker plate and
screens

Export screw configuration (with or without operating

conditions, with or without element identification) as bitmap
images, then paste into any Windows application (i.e.
PowerPoint, Word, etc.)

Output of Program WinTXU Version 3.2

Date: 02/11/14

Project ID:
2223
Version: 104
Author:
Creation Date: 06/18/12 Last Modification Date: 11/12/13
Project:
No Name
Project File: C:\Project Screw 101
Extruder:
Machine Type ABC
Shaft Length: 1276.00 mm 39.88 L/D
Barrel Length: 1286.00 mm 40.19 L/D
Screw Length: 1280.00 mm 40.00 L/D
Screw Offset: -0.00 mm
Configuration Complete

Screw:

53 Elements Configured L(mm) L/D

01 C2F-16/24-A
15.00 .47 0 1
02 C2F-16/24-B
29.00 .91 0 1
03 S040R040
69.00 2.16 0 1
04 SKK060R060
129.00 4.03 0
05 SKK060R060
189.00 5.91 0
06 KB910N032C
221.00 6.91 0
07 SKK056R056
277.00 8.66 0
08 KB910N032C
309.00 9.66 0

Offs Barrel

1
2
2
2
3

Save/export Summary as text file:

complete listing of barrel/screw/die
configuration (and operating
conditions)

The following screen shots show WinTXS

Simulation Software assembly of the virtual
extruder is exactly the same as WinTXU

Specification for breaker plate,

allows WinTXS to compute
pressure drop

Specification for screens, allows

WinTXS to compute pressure drop

Select one of the default die plates

or click on Custom to enter new
die geometry

Adjusting coefficients are used to

tune calculated pressure drop
and temperature rise to
measured/actual data

WinTXS Simulation Parameters

Can simulate screw/barrel wear

conditions

WinTXS Simulation Parameters

Enabling the
DEBUG mode in
WinTXS provides
adjustment of melting
model, heat transfer,
viscosity and shear
rate. Adjusting these
parameters, WinTXS
simulation results are
calibrated to match
actual data for a
given set of operating
conditions.

WinTXS Simulation Parameters

Once the DEBUG
parameters are
identified that
correlate simulation
results with reality
(e.g. torque, melt
temp) subsequent
changes in operating
parameters, screw
design, screw
diameter, use these
same values!

Calibration Factors are the single largest advantage between WinTXS

and all other simulation software products currently available

Calibration Factors are used to adjust location and extent of melting, for
example, to correlate with presence of low-melting additives feeding with
polymer

Calibration Factors are used to adjust frictional energy over length of screw

Adjusting frictional energy over length of screw results in more or less

viscous heating used to adjust for actual discharge temperature

Define global conditions for

simulation

Select polymer for simulation (only one

polymer can be used per simulation run)

Define solid fillers/liquid additives for

simulation

Can simulate up to three different

solid fillers and three different liquid
additives

Define process parameters for

simulation : feed rate, screw
speed, barrel temp settings

Head pressure can be calculated

from die geometry or input as a
process parameter

Material selection/editing is selected using the Materials tab

Polymer properties are user defined

Polymer requires definition of rheological model

Click on Generic Viscosity button to

create a new resin with specified
viscosity

WinTXS can simulate using generic material properties select generic

material type (e.g. PP, LDPE, PA6, PC, etc.) and specify melt flow rate.
This unique feature, combined with Calibration Factors (DEBUG parameters)
can provide quick and relatively accurate results without having actual material
characterization simulation results can be adjusted to match actual machine
performance (torque, melt temp, etc.)

Polymer requires definition of solid state properties

Solid additive requires definition of thermal properties

Liquid additive parameters

Liquid additives can be specified

as having a diluting effect (e.g.
modify viscosity up/down) or a
plasticizing effect (modify Tg).

Simulation summary: prediction of discharge temperature,

specific energy and average residence time

Solids conveying is not well modeled in 1D simulation, melt conveying

is very accurate

Pressure distribution can be used to diagnose vent flooding, vacuum

problems (can evaluate alternate screw designs in pumping section)

Location /position of resin melting is critical to optimize screw design

Power distribution can be used to determine kW in each mixing section

WinTXS can measure residence time from any position to end of machine
(e.g. amount of time a specific additive may spend in the machine or at
elevated temperature)

Heat transfer is calculated to maintain barrel temperature at setpoint

Mixing Index is a relative measure

of mixing quality, is influenced by
screw design and operating
conditions.

Mixing Index is a quantitative measure, is used to optimize screw designs

and for scale-up to other/larger machine

Stress Index is a measure of shear

stress, is calculated as the product
of viscosity and incremental
residence time

Stress Index is used, for example, to optimize dispersion of filler (e.g.

maximize stress index in a particular mixing section) or mixing of fiber
(e.g. minimize stress index to avoid glass breakage)

PolyTech WinTXU, WinTXS Software Packages

Single-User License
Permanent, single-user license (via USB hardware key)
Database contains up to three extruder models
Additional cost for each extruder model added to database
Fee for each additional user license (i.e. additional hardware keys)

Network License
Permanent, password-protected license

Database contains up to three extruder models

Fee to add extruders to database

Contact Us
Tom Urban
James Drummond
Michelle Zhang
Bill Goehman
Jim Hayward

urbant@centuryextrusion.com
drummondj@centuryextrusion.com
zhangm@centuryextrusion.com
goehmanb@centuryextrusion.com
haywardj@centuryextrusion.com

For general inquiries

sales@centuryextrusion.com
(231) 947-6400

Website

www.centuryextrusion.com