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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - NEWEX (Investigation and development of a new generation of machines for the processing of composite and nanocomposites materials)

Teaser

Summary

The main research goal of the NEWEX project is the construction and testing of the new innovative extruder. By the application of new conceptions of vital parts: innovative active grooved feed section (IAGFS), original rotational barrel segment (ORBS) and special screw (SS) a completely new breakthrough technology of extrusion and operation of plasticizing systems will be achieved. It will ensure manufacturing the products of improved properties and will enable processing materials such as composites and nanocomposites that couldnâ€™t be processed so far, as well as other materials np. food materials, cosmetic and pharmaceutical.
In parallel to the main RTD activities the NEWEX project is aiming at industry-academia cooperation and transfer of knowledge between organizations from central-eastern and Western Europe. All the projectâ€™s activities will be performed by thoroughly planned secondments and appropriate hosting institutions between industrial and academic partners. The workplan consists of 7 Workpackages, out of which: WP1-4 focus on the investigation of extruder, extrusion process and extrudate properties and tasks aiming at the selection of the best solution of new extruder vital parts, than construction and testing of new generation extruder. WP5 concentrates on networking activities. WP6 aims at knowledge dissemination (participation in conferences, fairs, publications, etc.). WP7 is dedicated to management and administration of the whole project. The consortium consists of 6 organizations: 3 academic partners and 3 industry partners.

Work performed

During the reporting period all activities specified in the DoA were performed.
Initial state research and results were defined, low density polyethylene was extruded with powder nanofiller in the form of HNT with the addition of compatibiliser, especially the investigation of the extruder and extrusion process were conducted, determining material pressure distribution in the plasticizing system and extrusion head, temperature distribution in individual functional zones of the plasticizing system and extrusion head, screw torque, unit energy consumption, extruder and process efficiency, die swell, temperature of the extrudate, polymer output, extrusion speed, power conducted to the extruder, power transferred by the polymer for a low and high screw speed. Next, the investigation of the extrudate properties was performed, defining melt flow index MFR and MVR, heat deflection temperature HDT, temperature of phase transitions, degree of crystallinity and enthalpy, relationship of the specific volume to temperature and pressure, degree of polymer homogenization, microscope laboratory studies of the material structure, as well as Youngâ€™s modulus, ultimate tensile stress, breaking stress, strain at ultimate stress, strain at break, impact strength, hardness, linear shrinkage.
The concepts of innovative AGFS, ORBS and SS were prepared, CAD models were elaborated, boundary conditions were defined, modelsâ€™ digitalization were performed. Strength calculations were made, numerical analysis was conducted defining the output, melt temperature, power consumption, the length required for melting, the mixing degree and the viscous dissipation. Out of the concepts the best three ones were selected. The best three models of each vital element were used to design virtual models of a plasticizing system of the new extruder. Numerical calculations and simulations of the polymer flow in the new plasticizing systems were made.
All training and networking activites were conducted, 7 workshops and 1 training took place (7 additional workshops and trainings), e-learning platform and main website of the project were create, 6 international conferences were attended, at which 10 papers were presented, 1 invention fair was attended, 23 scientific papers and 5 local-thematic press articles were written, a progress report and a periodic report were submitted, Kick-off meeting, Mid-term meeting, MB and EAB meetings took place. The project was also promoted at 2 presentations during the events organised by National Contact Point.
Training, Transfer of Knowledge and Networking is carried out mainly by secondments. We completed WP1 and we are completing WP2 (4 tasks are completed, 1 task is in-progress and 1 task will be carried out in the future). 80 Secondments were planned and 86 took place (without T2.5, which is in-progress). The difference results from the necessity to adapt the number of Secondees to the scope of tasks and availability of human resources as well as organisation issues.
Project coordination and all Newex activities are based on GA 734205. Consortium has also CA signed prior to GA. The project is managed by MB. MB had 3 meetings. EAB had 2 meetings. All reports and deliverables from implementation of the project were submitted to REA.
IPRs issues in our project are regulated by GA and CA. IPR concern the following publications and patents. We are trying to publish papers in journals in which copyright do not go to the editor and there is a rule of no ghostwriting and no guest authorship. IPRs concerning patents are regulated by agreements between a Partner and a researcher.
The dissemination of results concerns mainly industrial property rights and publications. Untill now we obtained 1 trademark and we submitted 13 patent applications to the Polish Patent Office. Apart from patent applications we have 28 publications, all of them are uploaded on green open access repository: (https://depot.ceon.pl).

Final results

Newex is a unique solution which will allow SMEs to process polymers, composite materials and nanocomposites that could not have been processed so far or their processing was difficult because of too small flow rate index, small viscosity, too much of nanofiller or very big molecular weight. The solution proposed in the NEWEX project will allow the conscious influence on the extrusion process of these materials by changing the structural features of the grooved extruder section during the extrusion process. We expect that our process will be more effective than the conventional extrusion process, we will be able to extrude more material in a shorter time, the process will be more efficient and the unit energy consumption will be smaller. This applies not only to the polymer processing industry but also to the cosmetics and food industry. The project complies with the principle of sustainable development and has a positive impact on the principle of sustainable development by reducing energy consumption and producing less waste. The use of our machines will increase the competitiveness of enterprises, their turnover and employment.
All Training, Transfer of Knowledge and Networking activities in Newex project contribute to broadening the participants\' knowledge, understanding problems at the university and in the industry. We hope that it will have a positive impact on research knowledge and expertise, quality of scientific output (publications, patents), awareness of open access to scientific publications and research data, management skills, grant/proposal writing skills, knowledge of IPR, ability to build and maintain international/intersectoral partnerships, as well as presentation and communication skills. The project will also have an impact on career, personal and professional development, employability and overall satisfaction.