Polymer Melt Extrusion Research Articles

Multiphysics modeling and simulation of monolayer flow and die swelling in industrial tube extrusion process

AbstractIn a regular extrusion process for thermoplastic specimen, the material behavior in dies and its rheological properties have a major influence on the mechanical properties and the quality of the extruded product. This study outlines the multiphysical model, which has been adapted to address the specific issues associated with polyamide 12 polymer extrusion. A series of numerical simulations, based on the modeling of material behavior, have been conducted using the computational code Comsol Multiphysics®. These simulations have been applied to the study of polymer melt flows through an industrial extrusion die. The objective of this study is to analyze the influence of the imposed extrusion parameters on the physical field distribution and the material displacement within the die. The die swell at the exit of the extrusion die has been investigated as a function of the imposed pressure. The progression of the polymer flow front inside the extrusion tool and the swelling rates have been analyzed. In particular, the phenomenon of delayed swelling at high pressure has been highlighted at high pressure.Highlights Polymer swelling at industrial extrusion die exit is investigated. Polymer melt extrusion within industrial extrusion tool is numerically simulated. Flow front progression and extrudate swell are analyzed. Effect of extrusion pressure on instabilities and die swell is highlighted.

The polymer diffusive instability in highly concentrated polymeric fluids

The extrusion of polymer melts is known to be susceptible to ‘melt fracture’ instabilities, which can deform the extrudate, or cause it to break entirely. Motivated by this, we consider the impact that the recently discovered polymer diffusive instability (PDI) can have on polymer melts and other concentrated polymeric fluids using the Oldroyd-B model with the effects of polymer stress diffusion included. Analytic progress can be made in the concentrated limit (when the solvent-to-total-viscosity ratio β→0), illustrating the boundary layer structure of PDI, and allowing the prediction of its eigenvalues for both plane Couette and channel flow. We draw connections between PDI and the polymer melt ‘sharkskin’ instability, both of which are short wavelength instabilities localised to the extrudate surface. Inertia is shown to have a destabilising effect, reducing the smallest Weissenberg number (W) where PDI exists in a concentrated fluid from W∼8 in inertialess flows, to W∼2 when inertia is significant.

Flow analysis of screw extrusion in three-dimensional concrete printing

Recent advances in three-dimensional concrete printing necessitated the detailed understanding of the operation and performance of screw extruders. This paper shows that the volumetric output rate can be approximated using the rotating barrel and stationary screw assumption (drag flow equation), which is used routinely in polymer melt extrusion calculations. Verification is provided by comparisons to experimental results available in the literature and to computer flow simulations for fluids with yield stress. Significant insight is obtained using fully three-dimensional simulations. This includes particle pathlines, which form “a helix within a helix,” axial pressure profiles, and the effect of yield stress, which is relatively small on the output rate but large on torque and power. The computer simulation also predicts unyielded flow zones in the extruder channel at low screw rotation speeds.

Optimization of Non-Newtonian Flow through a Coat-Hanger Die Using the Adjoint Method

The use of coat-hanger dies is prevalent in the plastic film and sheet extrusion industry. The product quality and the power of the extrusion machine depend on the uniformities of the fluid velocity at the exit and the pressure drop. Die manufacturers face the challenge of producing coat-hanger dies that can extrude materials uniformly and with a minimal pressure drop. Previous studies have analyzed the die outlet’s flow homogeneity and pressure drop using various numerical simulations. However, the combination of the scheme programming language together with the Adjoint Method of Optimization has yet to be attempted. The adjoint optimization method has been demonstrated to be beneficial in addressing issues related to shape optimization problems and it may also be beneficial in optimizing the design of dies used in polymer melt extrusion. In this study, the proposed innovations involve incorporating both the Scheme programming language and Adjoint solver to examine and optimize the coat hanger’s flow homogeneity and pressure drop. Before optimization, the outlet velocity was almost 10 times higher at the die center than at the edges but after optimization, it became more uniform. The proposed optimized coat-hanger die geometry results in more uniform melt flow as demonstrated by the velocity contour plot and the outlet velocity graph in the die slit area, reducing the deviation value from 0.097 to 0.015. Additionally, the mass flux variance across the die outlet decreased by 71.6% from 0.015069 kg m−2 s−1 to 0.004281 kg m−2 s−1. Therefore, using this method reduces the amount of time wasted on trial and error or other optimization techniques that may be limited by design constraints.

Non-destructive evaluation of melt-extruded part quality using in situ data

PurposeThis study aims to collect real-time, in situ data from polymer melt extrusion (ME) 3D printing and use only the collected data to non-destructively identify printed parts that contain defects.Design/methodology/approachA set of sensors was created to collect real-time, in situ data from polymer ME 3D printing. A variance analysis was completed to identify an “acceptable” range for filament diameter on a popular desktop 3D printer. These data were used as the basis of a quality evaluation process to non-destructively identify spatial regions of printed parts in multi-part builds that contain defects.FindingsAnomalous parts were correctly identified non-destructively using only in situ collected data.Research limitations/implicationsThis methodology was developed by varying the filament diameter, one of the most common reasons for print failure in ME. Numerous other printing parameters are known to create faults in melt extruded parts, and this methodology can be extended to analyze other parameters.Originality/valueTo the best of the authors’ knowledge, this is the first report of a non-destructive evaluation of 3D-printed part quality using only in situ data in ME. The value is in improving part quality and reliability in ME, thereby reducing 3D printing part errors, plastic waste and the associated cost of time and material.

A rheology and processing study on controlling material and process defects in polymer melt extrusion film casting using polymer blends

The primary objective of this research paper is to control the material and process defects in polymer melt extrusion film casting (EFC) process for linear chain architecture polyethylene (PE) resins through polymer blending methodology. Extrusion film casting is a well-known industrially important manufacturing process that is used to manufacture thousands of tons of polymer/plastic films/sheets and coated products. In this research, the necking defect in an EFC process has been studied experimentally for a linear low density polyethylene (LLDPE) resin and attempts have been made to control its necking by blending in a long chain branched (LCB) low density polyethylene (LDPE) resin. The blending methodology is based on the understanding that a LDPE resin displays enhanced resistance to necking as compared to the LLDPE resin. It is found that added LDPE resin enhances necking resistance for the primary LLDPE resin. Further, as the LDPE concentration increases in the blend formulation, the necking is further reduced as compared to pure LLDPE. Analogous to past studies on EFC of linear and long chain branched architecture containing PEs, it is observed that as the LDPE is increased in the blend formulations, the formulations displayed enhanced melt elasticity and extensional strain hardening in rheological studies. It is concluded from this study that polyethylene resins having linear chain architecture can be made amenable to enhanced resistance to necking using appropriate amount of a long chain branched resins. Finally, process defects such as the draw resonance onset could be shifted to higher draw ratios as the LDPE level is increased in the LLDPE-LDPE blend formulation.

Modeling the thermodynamics and kinematics of spherical particle dispersion in polymer melts: Model derivation and simulation analysis

AbstractA cohesive binding‐force‐based model has been developed to predict solid particulate agglomerate break up in fluids sheared volumes leading to particle dispersion in polymer melt extrusion processes. Particle—particle, particle—polymer, and particle—modifier—polymer interactions are modeled using adaptions from Hamaker's approach. This leads to an analytical molecular attraction approach that captures the effects of: (1) particle‐particle agglomerate cohesion based on material properties and structure, (2) the effect of surface modifiers on cohesive strength and particle separation, (3) polymer wetting and melt adhesion leading to medium‐agglomerate stress transfer, (4) applied fluid mechanical stress and melt temperature, and (5) residence time. In this paper, the model is evaluated, and several predicted effects of processing parameters on reduction of agglomerate size are calculated and graphically presented from this phase of the research. The predicted trends are consistent with the published data in the literature.

Simulation of Tubular Film Extrusion of Polymer Melts

Abstract A model of the tubular film process is presented which includes power law non-linear rheological behaviour with temperature and crystallinity dependent properties. The heat transfer modelling uses an experimental correlation for the heat transfer coefficient. It is shown that except at low activation energies of viscous flow, the power law exponents have little influence on bubble shape. For activation energies of viscous flow of 11 kcal/mol and more, the temperature dependence of rheological properties dominates bubble shapes at fixed drawdown ratios, blowup ratios and frostline heights. Low activation energies of viscous flow produced wine glass shaped bubbles, while high activation energies cause rapid increases in bubble radius after the die exit.

Ductile behavior and heat transfer efficiency in polymer extrusion by self-controlled “flipping melt-pancakes” with multi-fields synergy

A new design approach of “Flipping Melt-Pancakes” structure was proposed to improve the ductile behavior and heat transfer capacity for polymer melt extrusion. Three-dimensional numerical analysis of novel proposed structures was implemented compared with Maddock element and conventional screw that are commonly used in industry. Results indicated that flow patterns of polymer fluid affected by the screw configurations, inducing different ductile deformation, i.e., shear deformation occurred in Maddock channel and torsional deformation yielded in the “Flipping Melt-Pancakes” structure. Deformation flow patterns can contribute to radial mass transfer, achieving effective exchange of local heat and making temperature distribution more uniform. Besides, the change of velocity direction brought by the circumferential movement facilitated the synergy between velocity and temperature gradient and, improved heat transfer. The novel proposed structure based on the polymeric multi-fields synergy principle- “Flipping Melt-Pancakes” structure- has good heat transfer properties, low pressure loss and good synergy effect, reflecting that the field synergy principle can be applied to optimize the screw structures in polymer processing. It provides a new theoretical perspective to solve the increasingly severe challenges due to the insufficient control of mass transfer and heat management in plasticization process of extrusion or injection.

Evolution of the Surface Structure and Functional Properties of the Electroconducting Polymer Coatings onto Porous Films

Composite systems containing electroconducting polymer coatings (polyaniline and polypyrrole) applied to porous films of semicrystalline polymers (polyethylene, polypropylene, and polyvinylidene fluoride) have been prepared. Porous supports were obtained in the process based on polymer melt extrusion with subsequent annealing, uniaxial extensions, and thermal stabilization. Conducting coatings were formed by the oxidative polymerization of the monomers directly onto the porous supports. The structure (overall porosity, permeability, pore sizes, factor of orientation) and morphology (specific surface and character of the film surface) of the supports were characterized by sorptometry, filtration porosimetry, atomic force microscopy (AFM), and X-ray scattering techniques. It was observed that the porous supports have a strongly developed relief surface which is formed in the pore formation process. It was proven by scanning electron microscopy (SEM) that the porous supports have an oriented structure, and the surface of the composites is defined by the morphology inherent in the conducting component. It was shown that these composites (porous support/conducting coating) demonstrate electric conductivity both along the surface and between surfaces. It was demonstrated that the deposition of conducting coatings leads to an increase in the water wettability of the composites compared with pronounced hydrophobic supports. The composites are characterized by good adhesion between components due to a relief film surface as well as high mechanical strength and elasticity provided by the oriented character of the supports.

Flow visualization by Matlab® based image analysis of high-speed polymer melt extrusion film casting process for determining necking defect and quantifying surface velocity profiles

Abstract The primary objective of this research paper is to detect and quantify the necking defect and surface velocity profiles in high-speed polymer melt extrusion film casting (EFC) process using Matlab® based image processing techniques. Extrusion film casting is an industrially important manufacturing process and is used on an industrial scale to produce thousands of kilograms of polymer films/sheets and coated products. In this research, the necking defect in an EFC process has been studied experimentally and the effects of macromolecular architecture such as long chain branching (LCB) on the extent of necking have been determined using image processing methodology. The methodology is based on the analysis of a sequence of image frames taken with the help of a commercial CCD camera over a specific target area of the EFC process. The image sequence is then analyzed using Matlab® based image processing toolbox wherein a customized algorithm is written and executed to determine the edges of the extruded molten polymeric film to quantify the necking defect. Alongwith the necking defect, particle tracking velocimetry (PTV) technique is also used in conjunction with the Matlab® software to determine the centerline and transverse velocity profiles in the extruded molten film. It is concluded from this study that image processing techniques provide valuable insights into quantifying both the necking defect and the associated velocity profiles in the molten extruded film.

Origin of the Sharkskin Instability: Nonlinear Dynamics.

The appearance of surface distortions on polymer melt extrudates, often referred to as sharkskin instability, is a long-standing problem. We report results of a simple physical model, which link the inception of surface defects with intense stretch of polymer chains and subsequent recoil at the region where the melt detaches from the solid wall of the die. The transition from smooth to wavy extrudate is attributed to a Hopf bifurcation, followed by a sequence of period doubling bifurcations, which eventually lead to elastic turbulence under creeping flow. The predicted flow profiles exhibit all the characteristics of the experimentally observed surface defects during polymer melt extrusion.

Ultrasonically enhanced flow rate of polymer melt extrusion

Ultrasonically enhanced flow rate of polymer melt extrusion

Ultrasonically enhanced flow rate of polymer melt extrusion

Ultrasonically enhanced flow rate of polymer melt extrusion

Orientation Efforts as Regulatory Factor of Structure Formation in Permeable Porous Poly(vinylidene fluoride) Films

The manufacturing process of poly(vinylidene fluoride) microporous films containing through flow channels and permeable to liquids has been elaborated. The process is based on polymer melt extrusion with subsequent stages of annealing, uniaxial extensions (“cold” and “hot” drawing), and thermal stabilization. The effect of orientation parameters (melt draw ratio and extension degrees) on overall porosity, permeability, morphology, and content of polar piezoactive β-phase in crystalline structure of the films was investigated by filtration porosimetry, sorptometry, scanning electron microscopy, X-ray scattering, and mechanical properties measurements. It is shown that the through pores were formed by a percolation mechanism. It is observed that permeability and the β-phase content increased with the growth of extension degree at the pore formation stages but the portion of β-crystallites decreased with increasing melt draw ratio at extrusion, which permitted to regulate the combination of through permeability and piezoactivity values by variation of the preparation process parameters.

Ordering Effects and Percolation in the Structure Formation Process of the Oriented Polyolefin Porous Films.

Structure transitions and mechanism of the formation of superlattices lamellae in microporous polyolefin (polyethylene and polypropylene) films obtained in the process based on polymer melt extrusion followed by annealing, uniaxial extension and thermal fixation have been studied by statistical analysis of electron microscopy images of the film surface. The structure of the porous films prepared in the multistage process has been studied by SEM, gravimetry and permeability measurements. It has been shown that the pore formation at the stage of uniaxial extension is accompanied by the ordering of lamellae and their self-organization controlled by spin draw ratio and annealing temperature. It was established that an increase of these parameters lead to the transition of disorder-order type. The effect of preparation conditions on the ordering process of regular spatial lattices of lamellae has been discussed.

Controlling Necking in Extrusion Film Casting Using Polymer Nanocomposites

ABSTRACTThe research described was concerned with the effect of layered-silicate-based organically modified nanoclay fillers on controlling the extent of necking in a polymer melt extrusion film casting (EFC) process. We show that a linear polythylene resin (such as a linear low-density polyethylene—LLDPE) filled with a very low percentage of well-dispersed (or intercalated) nanoclay displays an enhanced resistance to the necking phenomenon. In general, melt-compounded nanoclay-filled LLDPE resin formulations displayed a higher final film width (less necking), thus a lower final film thickness (greater draw down for the same draw ratio), and cooled down faster when compared to the base LLDPE resin. Incorporation of nanoclay filler in the mainly linear chain LLDPE resin led to significant modification of the melt rheological properties that, in turn, affected the melt processability of these formulations. Primarily, the intercalated nanoclay-filled LLDPE formulations displayed the presence of strain-hardening in unaxial extensional rheology. Additionally, the presence of well-dispersed nanoclay in the LLDPE resin led to a display of prominent extrudate swell indicating the presence of melt elasticity in such formulations. The presence of melt elasticity, as shown by shear rheology and strain-hardening, observed by uniaxial extensional rheology, contributed to the LLDPE nanoclay formulations displaying an enhanced resistance to necking for these films. It can be concluded that linear chain polymers susceptible to necking in an EFC process can be made more resistant to such necking by using nanoclay fillers at very low levels of loading.

The effect of gas assisted length on polymer melt extrusion based on the gas-assisted extrusion technique

In this study, the gas-assisted technique was used into the process of polymer melt extrusion to overcome the extrudate swell problem. The gas length is an important factors in the gas-assisted extrusion technique. To ascertain the mechanism of the gas-assisted extrusion technique, and to determine the optimal gas length, the effect of gas length on the extrudate swell ratio of melt was numerically investigated. In finite element numerical simulation, PTT constitutive model and full slip boundary condition were used to achieve the gas-assisted mode. Compared with the traditional no gas-assisted extrusion, numerical results showed that the extrudate swell problem was well eliminated by the gas-assisted method. Moreover, the extrudate swell of melt decreased with the increasing of the gas length because the pressure and shear stress of melt were greatly decreased. Moreover, the flow velocity of melt is uniform at the die outlet.

New insights into the use of multi-mode phenomenological constitutive equations to model extrusion film casting process

This article is concerned with the effect of the individual viscoelastic relaxation modes of a polymer melt on its behavior in polymer melt extrusion film casting process. We compare the predicted versus experimentally obtained film necking or neck-in profile as a function of draw ratio. The predicted necking profile was obtained using well-established one-dimensional isothermal flow kinematics and consisted of using two different phenomenological constitutive equations, upper convected Maxwell and Phan-Thien–Tanner, with a discrete spectrum of relaxation times. The numerical simulations, containing the two different phenomenological constitutive equations, provided an insight into the effect of the slow and the fast relaxing modes on the stresses, strains, and strain/extensional rates that develop in the molten polymer film as it is stretched from the die exit to the chill-roll. The slow relaxing modes follow trends that are directly proportional to strain (similar to Hookean solids), whereas the fast relaxing modes follow trends that are directly proportional to the stretch rate (in accordance with Newton’s law of viscosity). Comparing the numerical predictions with the experiments showed that predictions using the upper convected Maxwell constitutive equation best described the long-chain branched polymers (like low-density polyethylene, which shows extensional strain hardening) in the extrusion film casting process. On the other hand, predictions using the Phan-Thien–Tanner constitutive equation best described the linear polymers (like linear low-density polyethylene, which does not show noticeable extensional strain hardening) in the extrusion film casting process.

First normal stress difference and in-situ spectral dynamics in a high sensitivity extrusion die for capillary rheometry via the ʽhole effect’

The development of a high sensitivity polymer melt extrusion flow instability detection die capable of estimating the normal stress differences of polymer melts during capillary rheometry tests via the 'hole effect' is presented here as proof-of-principle. Two polymer melts, a low density polyethylene (branched topology) and a high density polyethylene (linear topology), were tested in a variety of experimental configurations with the purpose of determining optimal conditions for performing normal stress difference measurements. The data was compared with rotational rheometry oscillatory shear measurements analyzed via the Laun rule. It is shown that it is possible to estimate the first normal stress difference in the capillary die, whereas the second normal stress difference cannot be determined within the experimental errors using the current configuration design. Furthermore, the influence of the induced streamline curvature via the 'hole effect' on the onset and development of melt flow instabilities is simultaneously assessed. It is shown that the hole depth has a stabilizing influence, i.e. the onset of instabilities occurs at higher shear rates, in the long chain branched polymer tested, whereas for the linear polymer tested it has a destabilizing effect on the stick-slip instability i.e. the onset of stick-slip occurs at lower shear rates.