Abstract: The profile curve design method and the mathematical model of conjugate surfaces of twin-screw kneader used for high viscosity material mixing, transportation and malaxating are established according to principle of gear engagement. One novel twin-screw kneader and the equations of the profile curves of the rotors as well as the rotor design are put forward, and the female and male rotor structures are designed. The working principles of the twin screw kneader are analyzed. The numerical simulation for dynamic characteristics of the flow field of the twin-screw kneader is carried out. The numerical simulation model of twin-screw kneader is established, and the three-dimensional, isothermal and steady numerical analysis of non-newtonian fluid is presented based on computational fluid dynamics (CFD) theory, and the characteristics under the conditions of different speeds and center distances such as the distribution of pressure and velocity field, the maximum shear stress, the mass flow rate and so on, are studied. Based on Fluid-solid coupling theory, the effect of different working conditions, such as fluid pressure, torque, on the twin-screw rotors’ stress and deformation is studied by solving the fluid solid coupling equations between internal fluid of kneader and the twin-screw rotors. The results provide a theoretical basis for reasonable designing and optimization of technical parameters for the novel twin-screw kneader.

Key words: Flow field dynamics characteristics, Numerical simulation, Rotor profiles, Twin-screw kneader