Development of experimental techniques and simulation methods to analyze mixing in co‐rotating twin screw extrusion

Currently, the selection of elements and operating conditions in the mixing of various materials in a corotating twin screw extruder is an art which requires previous experimental studies. In this report, we outline various experimental and theoretical tools developed to investigate the mixing process in a fully intermeshing corotating twin screw extruder. The thermomechanical history of mixing is simulated employing the finite element method. To verify the numerical findings, experimental techniques were developed to investigate the goodness of mixing of samples collected from a 50.8 mm, “clam shell” design, Baker‐Perkins twin screw extruder.