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We have developed a three-dimensional analysis technique for non-Newtonian flow in a melt conveying zone of a counter-rotating intermeshing twin screw extruder by the finite element method. We used a reference frame moving with the apparent velocity of the screw flight because the analysis zone changes with time for the stationary reference frame. As a result, the complex transport mechanism in the twin screw extruder could be understood from the obtained velocity fields. We evaluated the flow rate for various kinds of leakage flow for varying screw geometries. It was found that the flow rate of interchanged fluid which transfered from one screw to the other became larger with increasing side gap and with decreasing calender gap. We also calculated the maximum shear stress distribution which was an important characteristic of the mixing performance. Furthermore, we estimated the temperature rise by viscous heat generation which is related to the thermal degradation of the polymers.

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