Optimization and Simulation of Extrusion Parameters in Polymer Compounding: A Comparative Study Using BBD and 3LFFD

The researchers looks at process characteristics in order to improve color choices and create more accurate simulation models, in this research paper. The processing factors evaluated were speed (Sp), temperature (T), and feed rate (FRate). We used Box-Behnken Design (BBD) and the three-Level-Full-Factorial Design (3LFFD) response surface techniques to adjust uniform processing settings. This study employed an experimental approach to optimize process parameters while holding all other variables constant. Statistical and numerical optimization were both made possible by the Design Expert software, which also helped with experimental design. We used this technique to generate a statistical equation for simulated regression models. The optimal tristimulus color values have the smallest color variance (dE*). The created model and experimental data passed all diagnostic tests, showing that the model is statistically valid. The three examined parameters had a significant effect on the color parameters dL*, da*, and db*, as well as specific mechanical energy (SME), according to the Analysis of Variance (ANOVA). Furthermore, we calculated specific mechanical energy for the experimental trials and found that it decreased as the FRate increased. The study concludes by comparing the two design models to determine which produces the best color quality. Choosing the right process settings is crucial for reducing color fluctuations (dE*). Furthermore, during the experimental trials, we performed microscopic characterization, including agglomeration level assessments. To determine pigment dispersion, the collected data was analyzed using Scanning-Electron Microscopy (SEM) as well as Micro-CT-scanner pictures (MCT). This work contributes to addressing potential design and manufacturing difficulties that affect color variability and waste minimization for diverse chemical grades, thereby encouraging environmentally friendly operations. Regarding the BBD. The processing circumstances indicate that 728.38 rpm, 274.23 °C, and 24.44 kg/hr are closest to the target specifications. In addition, overall the lowest deviation=0.26 while 87% is the maximum design attractiveness. We are discussing the three-Level Full Factorial Design (3LFFD). Generally the a maximum desirability of 77% and a minimum tolerable color variation (dE*) of 0.25, we determined that 741.27 rpm, 245.26 °C, and 24.72 kg/hr were the ideal process parameters. These results show that the processing parameters used to generate the output have a significant impact on its quality. To reduce the variation and improve appeal more modifications This study compares the two generated designs and discovers that both sets of process parameters were statistically significant, with BBD being the preferred option for selection needed, resulting in even better outcomes in future experiments.