LAUSR

Abstract Mixing process of a highly viscous Newtonian fluid in a horizontal self-cleaning twin-shaft kneader was simulated by means of finite element method combined with mesh superposition technique. Particle tracking technique was carried out based on the velocity profiles to evaluate the mixing performance. There exists a strong intermeshing interaction between the kneading bars mounted on the rotating shafts in the overlapping zone, which can disrupt the cluster and promote the material exchange in the angular position. The intermeshing kneading bars allow the infinitesimal lines associated with the material points to reorient and continue to stretch. The periodic intermeshing leads to self-cleaning and chaotic mixing characteristics. The horizontal twin-shaft kneader is efficient for mixing highly viscous fluids due to the intermeshing of kneading bars.