Effects of Operating Parameters on Mixing Performance and Multi-Objective Optimization of Twin-Blade Planetary Mixer in Viscous Systems

The twin-blade planetary mixer is critical for processing highly viscous materials in the chemical and polymer industries, yet optimizing its mixing characteristics alongside energy efficiency remains challenging. This study investigates the twin-blade planetary mixer, using computational fluid dynamics simulation methods to analyze the operating parameters and multi-objective optimization of performance in viscous systems. First, the multi-axis stirring process was simulated numerically based on the Planetary Motion Method, revealing the working process at the cross-section and of the blades, thereby unveiling a mixing mechanism driven by cyclic transitions between local shear-intensive kneading and global convective circulation. Then, through orthogonal experiments and ANOVA, the dominant role of the hollow blade’s self-rotation speed on performance was clarified. Furthermore, based on Kriging and NSGA-II, with LINMAP employed for decision making, an optimal parameter combination, specifically a hollow blade self-rotation speed of 94.86 rpm, a speed ratio of 0.063, and a blade-to-bottom height of 2.79 mm, successfully achieved an 8.15% reduction in power consumption, a 20.03% increase in global axial flow, and a 5.01% enhancement in maximum kneading pressure.