Dynamic modeling and simulation of mass, momentum, and energy transport in a single-screw plastic extrusion process

Dynamic modeling and simulation of mass, momentum, and energy transport in a single-screw plastic extrusion process | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Dynamic modeling and simulation of mass, momentum, and energy transport in a single-screw plastic extrusion process Fabian Luna, Juan C. Maya, Farid Chejne This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7900794/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 19 Mar, 2026 Read the published version in Multiscale and Multidisciplinary Modeling, Experiments and Design → Version 1 posted 12 You are reading this latest preprint version Abstract This study presents a novel semi-physical phenomenological model that addresses a significant gap in the literature by incorporating dynamic 1D mass, momentum, and energy balances across all zones of a single-screw extruder. The model was implemented for a conventional screw geometry with a smooth feed section. The methodology involved spatial discretization using upwind finite difference schemes, resulting in a system of differential-algebraic equations (DAE). This system was solved numerically and validated with experimental data from an industrial extruder processing polypropylene. Simulation results demonstrate that the model accurately predicts plastification profiles, melt temperatures, and pressure distributions with low prediction errors. Mean Absolute Error (MAE) values of 7.45 × 10⁻⁶ m² for the solid flow area, between 0.51 and 8.96 bar for pressure, and 1.66°C for the melt temperature were obtained. A key feature is its computational efficiency, with simulations requiring a maximum time of 875 seconds. As far as we know, this work presents the first dynamic 1D model that unifies all key extrusion zones in a fully coupled manner. The key novelty of this work is that its rapid and accurate predictive capabilities make it a valuable tool for screw geometry optimization, sensitivity studies, and integration into digital-twin frameworks to support decision-making in industrial operations. extrusion dynamic modeling polymers polypropylene single-screw extruder Full Text Additional Declarations No competing interests reported. Supplementary Files GraphicalAbstract.jpg Cite Share Download PDF Status: Published Journal Publication published 19 Mar, 2026 Read the published version in Multiscale and Multidisciplinary Modeling, Experiments and Design → Version 1 posted Editorial decision: Revision requested 26 Nov, 2025 Reviews received at journal 18 Nov, 2025 Reviews received at journal 03 Nov, 2025 Reviews received at journal 31 Oct, 2025 Reviewers agreed at journal 25 Oct, 2025 Reviewers agreed at journal 22 Oct, 2025 Reviewers agreed at journal 21 Oct, 2025 Reviewers agreed at journal 21 Oct, 2025 Reviewers invited by journal 21 Oct, 2025 Editor assigned by journal 21 Oct, 2025 Submission checks completed at journal 21 Oct, 2025 First submitted to journal 19 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7900794","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":534748942,"identity":"b989d2f3-4528-4e3b-9b6a-90bb73abb326","order_by":0,"name":"Fabian Luna","email":"","orcid":"","institution":"National University of Colombia","correspondingAuthor":false,"prefix":"","firstName":"Fabian","middleName":"","lastName":"Luna","suffix":""},{"id":534748943,"identity":"7c700c24-db2b-4b74-ba53-4464db34dc18","order_by":1,"name":"Juan C. 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process","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"multiscale-and-multidisciplinary-modeling-experiments-and-design","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"mmed","sideBox":"Learn more about [Multiscale and Multidisciplinary Modeling, Experiments and Design](https://link.springer.com/journal/41939)","snPcode":"41939","submissionUrl":"https://submission.nature.com/new-submission/41939/3","title":"Multiscale and Multidisciplinary Modeling, Experiments and Design","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"extrusion, dynamic modeling, polymers, polypropylene, single-screw extruder","lastPublishedDoi":"10.21203/rs.3.rs-7900794/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7900794/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study presents a novel semi-physical phenomenological model that addresses a significant gap in the literature by incorporating dynamic 1D mass, momentum, and energy balances across all zones of a single-screw extruder. The model was implemented for a conventional screw geometry with a smooth feed section. The methodology involved spatial discretization using upwind finite difference schemes, resulting in a system of differential-algebraic equations (DAE). This system was solved numerically and validated with experimental data from an industrial extruder processing polypropylene. Simulation results demonstrate that the model accurately predicts plastification profiles, melt temperatures, and pressure distributions with low prediction errors. Mean Absolute Error (MAE) values of 7.45 \u0026times; 10⁻⁶ m\u0026sup2; for the solid flow area, between 0.51 and 8.96 bar for pressure, and 1.66\u0026deg;C for the melt temperature were obtained. A key feature is its computational efficiency, with simulations requiring a maximum time of 875 seconds. As far as we know, this work presents the first dynamic 1D model that unifies all key extrusion zones in a fully coupled manner. The key novelty of this work is that its rapid and accurate predictive capabilities make it a valuable tool for screw geometry optimization, sensitivity studies, and integration into digital-twin frameworks to support decision-making in industrial operations.\u003c/p\u003e","manuscriptTitle":"Dynamic modeling and simulation of mass, momentum, and energy transport in a single-screw plastic extrusion process","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-01 00:59:02","doi":"10.21203/rs.3.rs-7900794/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2025-11-26T16:33:57+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-11-18T13:51:57+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-11-03T12:56:39+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-10-31T08:53:28+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"183770170045774352983286010004988732600","date":"2025-10-25T06:34:47+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"293819375449562216780819649581048292866","date":"2025-10-22T12:18:02+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"11763322094446066055364340787241104098","date":"2025-10-21T16:11:31+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"142077448904707687883774614119837122481","date":"2025-10-21T15:58:03+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-10-21T15:08:59+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-21T07:54:22+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2025-10-21T07:53:10+00:00","index":"","fulltext":""},{"type":"submitted","content":"Multiscale and Multidisciplinary Modeling, Experiments and Design","date":"2025-10-19T21:51:45+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"multiscale-and-multidisciplinary-modeling-experiments-and-design","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"mmed","sideBox":"Learn more about [Multiscale and Multidisciplinary Modeling, Experiments and Design](https://link.springer.com/journal/41939)","snPcode":"41939","submissionUrl":"https://submission.nature.com/new-submission/41939/3","title":"Multiscale and Multidisciplinary Modeling, Experiments and Design","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"ee828f0d-484a-4764-b640-4a7ff22657b5","owner":[],"postedDate":"November 1st, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-03-23T16:04:03+00:00","versionOfRecord":{"articleIdentity":"rs-7900794","link":"https://doi.org/10.1007/s41939-026-01181-2","journal":{"identity":"multiscale-and-multidisciplinary-modeling-experiments-and-design","isVorOnly":false,"title":"Multiscale and Multidisciplinary Modeling, Experiments and Design"},"publishedOn":"2026-03-19 15:59:11","publishedOnDateReadable":"March 19th, 2026"},"versionCreatedAt":"2025-11-01 00:59:02","video":"","vorDoi":"10.1007/s41939-026-01181-2","vorDoiUrl":"https://doi.org/10.1007/s41939-026-01181-2","workflowStages":[]},"version":"v1","identity":"rs-7900794","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7900794","identity":"rs-7900794","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}