To address the challenges of low automation， high danger， and poor uniformity in conventional charging processes of thermoplastic energetic materials， this study introduced a vertical screw charging technology and established a quantitative comprehensive performance evaluation method to guide process optimization， aiming to systematically enhance process efficiency， charging quality， and operational safety. Based on an analysis of the viscoelastic properties of the slurry， the rheological behavior of the slurry during extrusion under different process conditions and formulation components was simulated， and the formation mechanisms of high-temperature and high-pressure hot spots were investigated. The results show that increasing the solid content mass fraction from 75% to 85% significantly reduces the slurry flowability， with increases in flow field pressure and shear stress by 827% and 600%， respectively， and an increase in viscous heating by 384 kW·m^-3. These changes intensify the thermo-mechanical coupling behavior during screw extrusion， reduce process safety， and raise the process risk coefficient from 0.99 to 3.36. However， by adjusting the screw speed （within the range of 10 r·min^-1 to 30 r·min^-1） and incorporating metal particles to enhance the thermal conduction network among the barrel， slurry， and screw， the temperature fluctuation range can be reduced by 0.8 ℃ to 1.9 ℃， effectively suppressing the formation of local hot spots.