Modelling of paste flows subject to liquid phase migration

Particulate pastes undergoing extrusion can exhibit differential velocities between the solid and liquid phases, termed liquid phase migration (LPM). This is observed experimentally but understanding and predictive capacity for paste and extruder design is limited. Most models for LPM feature one-dimensional analyses. Here, a two-dimensional finite element model based on soil mechanics approaches (modified Cam-Clay) was developed where the liquid and the solids skeleton are treated separately. Adaptive remeshing routines were developed to overcome the significant mesh distortion arising from the large strains inherent in extrusion. Material data to evaluate the model’s behaviour were taken from the literature. The predictive capacity of the model is evaluated for different ram velocities and die entry angles (smooth walls). Results are compared with experimental findings in the literature and good qualitative agreement is found. Key results are plots of pressure contributions and extrudate liquid fraction against ram displacement, and maps of permeability, liquid velocity and voids ratio. Pore liquid pressure always dominates extrusion pressure. The relationship between extrusion geometry, ram speed and LPM is complex. Overall, for a given geometry, higher ram speeds give less migration. Pastes flowing into conical entry dies give different voids ratio distributions and do not feature static zones. Copyright q 2007 John Wiley & Sons, Ltd