In this paper, a detailed three-dimensional finite element method (3D FEM) study of the mixing performance of the Fusion screw geometry by using two different rheological models is presented. Special criteria characterising the mixing performance in dependence of the barrier undercut separating the waving channels are developed. A great mixing performance is achieved when a right balance in both dispersive and distributive parts of the mixing process is found. An optimal undercut of the barrier was found to be about 2 mm. Both rheological models were successfully used to validate data of the real experiment with an error less than 15%.
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