Three-dimensional isothermal flow of polymer melt in the kneading-disc element of an intermeshing co-rotating tri-screw extruder was simulated by using finite element package POLYFLOW. Based on the velocity fields calculated, flow patterns of the melt were analyzed, and particle trajectories were visualized. The numerical results indicated that, in intermeshing co-rotating tri-screw extruders,particles went through three intermeshing regions during one cycle around the screws, thus achieving better plasticating and mixing than intermeshing co-rotating twin-screw extruders. Flow in the central region was also studied by using particle tracking technique,and residence time distribution (RTD) and trajectories for particles in this region were presented. The simulation results showed that there was no stagnation in the central region. This study provided a clear insight into the flow mechanism of tri-screw extrusion. It also provided a new method for studies of flow mechanisms in other complicated mixers.
