Influence of wall slip on extrudate swell: a boundary element investigation

This paper reports a numerical study of the extrudate swell by a transient Boundary Element Method (BEM). Furthermore the fluid, which is modeled by a differential constitutive equation, is allowed to slip at the wall, where the slip velocity is a prescribed function of the wall shear stress. This function is a curve fit of the extensive data of Ramamurthy on linear low density polyethylene which incorporates two parameters: a critical wall shear stress above which slip occurs, and another parameter which governs the shape of the slip velocity versus shear stress curve. The results show that wall slip reduces both the amount of extrudate swell and the critical Weissenberg number above which our numerical scheme no longer converges.     

A marker-and-cell approach to viscoelastic free surface flows using the PTT model

This work is concerned with the development of a numerical method capable of simulating two-dimensional viscoelastic free surface flows governed by the non-linear constitutive equation PTT (Phan-Thien–Tanner). In particular, we are interested in flows possessing moving free surfaces. The fluid is modelled by a marker-and-cell type method and employs an accurate representation of the fluid surface. Boundary conditions are described in detail and the full free surface stress conditions are considered. The PTT equation is solved by a high order method which requires the calculation of the extra-stress tensor on the mesh contour. The equations describing the numerical technique are solved by the finite difference method on a staggered grid. In order to validate the numerical method fully developed flow in a two-dimensional channel was simulated and the numerical solutions were compared with known analytic solutions. Convergence results were obtained throughout by using mesh refinement. To demonstrate that complex free surface flows using the PTT model can be computed, extrudate swell and a jet flowing onto a rigid plate were simulated.     

Three-dimensional extrudate swell experimental and numerical study of a polyethylene melt obeying a memory-integral equation

The present work deals with the experimental and numerical features of the flow of a linear low-density polyethylene melt (LLDPE) at 160°C at the exit of a die of square cross-section. The rheological properties of the fluid are fitted by a Wagner's memory-integral constitutive equation. The characteristics of the extrudate jet are determined by optical means at different flow rates. The stream-tube analysis, already applied to two-dimensional extrudate swell problems involving rate and integral constitutive equations, is considered to simulate the flow field. The method avoids particle tracking problems related to integral models and allows computation of the unknown free surface by considering only a `peripheral stream tube' limited by the wall and the jet surface and an inner stream surface. Those boundary surfaces are determined by considering the conservation equations together with boundary condition equations, solved by the Levenberg–Marquardt optimization algorithm. The method leads to a considerable reduction in the number of degrees of freedom and the storage area. The numerical results are found to be generally consistent with the experimental data and highlight the growing importance of stress peaks due to the singularity at the exit when the flow rate increases.     

Numerical study of the combined effects of inertia,slip, and compressibility in extrusion of yield stress fluids

The axisymmetric extrudate swell flow of a compressible Herschel–Bulkley fluid with wall slip is solved numerically. The Papanastasiou-regularized version of the constitutive equation is employed, together with a linear equation of state relating the density of the fluid to the pressure. Wall slip is assumed to obey Navier’s slip law. The combined effects of yield stress, inertia, slip, and compressibility on the extrudate shape and the extrudate swell ratio are analyzed for representative values of the power-law exponent. When the Reynolds number is zero or low, swelling is reduced with the yield stress and eventually the extrudate contracts so that the extrudate swell ratio reaches a minimum beyond which it starts increasing asymptotically to unity. Slip suppresses both swelling and contraction in this regime. For moderate Reynolds numbers, the extrudate may exhibit necking and the extrudate swell ratio initially increases with yield stress reaching a maximum; then, it decreases till a minimum corresponding to contraction, and finally, it converges asymptotically to unity. In this regime, slip tends to eliminate necking and may initially cause further swelling of the extrudate, which is suppressed if slip becomes stronger. Compressibility was found to slightly increase swelling, this effect being more pronounced for moderate yield stress values and wall slip.     

A finite difference analysis of the extrudate swell problem

The extrudate swell phenomenon of a purely viscous fluid is analysed by solving simultaneously the Cauchy momentum equations along with the continuity equation by means of a finite difference method. The circular and planar jet flows of Newtonian and power-law fluids are simulated using a control volume finite difference method suggested by Patankar called SIMPLER (semi-implicit method for pressure-linked equations). This method uses the velocity components and pressure as the primitive variables and employs a staggered grid and control volume for each separate variable. The numerical results show good agreement with the analytical solution of the axisymmetric stick-slip problem and exhibit a Newtonian swelling ratio of 13.2% or 19.2% for a capillary or slit die respectively in accordance with previously reported experimental and numerical results. Shear thinning results in a decrease in swelling ratio, as does the introduction of gravity and surface tension.     

Prediction of extrudate swell in polymer melt extrusion using an Arbitrary Lagrangian Eulerian (ALE) based finite element method

Accurate prediction of extrudate (die) swell in polymer melt extrusion is important as this helps in appropriate die design for profile extrusion applications. Extrudate swell prediction has shown significant difficulties due to two key reasons. The first is the appropriate representation of the constitutive behavior of the polymer melt. The second is regarding the simulation of the free surface, which requires special techniques in the traditionally used Eulerian framework. In this paper we propose a method for simulation of extrudate swell using an Arbitrary Lagrangian Eulerian (ALE) technique based finite element formulation. The ALE technique provides advantages of both Lagrangian and Eulerian frameworks by allowing the computational mesh to move in an arbitrary manner, independent of the material motion. In the present method, a fractional-step ALE technique is employed in which the Lagrangian phase of material motion and convection arising out of mesh motion are decoupled. In the first step, the relevant flow and constitutive equations are solved in Lagrangian framework. The simpler representation of polymer constitutive equations in a Lagrangian framework avoids the difficulties associated with convective terms thereby resulting in a robust numerical formulation besides allowing for natural evolution of the free surface with the flow. In the second step, mesh is moved in ALE mode and the associated convection of the variables due to relative motion of the mesh is performed using a Godunov type scheme. While the mesh is fixed in space in the die region, the nodal points of the mesh on the extrudate free surface are allowed to move normal to flow direction with special rules to facilitate the simulation of swell. A differential exponential Phan Thien Tanner (PTT) model is used to represent the constitutive behavior of the melt. Using this method we simulate extrudate swell in planar and axisymmetric extrusion with abrupt contraction ahead of the die exit. This geometry allows the extrudate to have significant memory for shorter die lengths and acts as a good test for swell predictions. We demonstrate that our predictions of extrudate swell match well with reported experimental and numerical simulations.     

The compressible Newtonian extrudate swell problem

We solve the compressible Newtonian extrudate swell problem in order to investigate the effect of compressiblity on the shape of the extrudate. We employ a first-order equation of state relating the density to the pressure and use finite elements for the numerical solution of the problem. Our results show that the shape of the extrudate and the final extrudate swell ratio are not significanlty affected even at high compressibility values.     

聚合物熔体三维挤出胀大的数值模拟

采用有限元方法分析K-BKZ本构方程描述的聚合物熔体的三维挤出胀大.对于本构方程中偏应力张量的计算,首先给出质点的运动轨迹,分段求出局部的变形梯度张量,再求出整体的变形梯度、Cauchy-Green应变张量和 Finger应变张量,沿轨迹采用分段高斯积分计算应力.把应力作为方程的右端项,给出迭代方法,求解非线性方程组.并根据自由面处的边界条件,迭代得出出口处自由面的最终位置.对轴对称流道和矩形流道进行分析计算,并把结果与二维分析和实验结果进行了比较,显示方法是可行的.     

Solving viscoelastic free surface flows of a second‐order fluid using a marker‐and‐cell approach

This work is concerned with the numerical simulation of two‐dimensional viscoelastic free surface flows of a second‐order fluid. The governing equations are solved by a finite difference technique based on the marker‐and‐cell philosophy. A staggered grid is employed and marker particles are used to represent the fluid free surface. Full details for the approximation of the free surface stress conditions are given. The resultant code is validated and convergence is demonstrated. Numerical simulations of the extrudate swell and flow through a planar 4:1 contraction for various values of the Deborah number are presented. Copyright © 2006 John Wiley & Sons, Ltd.     

Extrudate swell of linear and branched polyethylenes: ALE simulations and comparison with experiments

Extrudate swell is a common phenomenon observed in the polymer extrusion industry. Accurate prediction of the dimensions of an extrudate is important for appropriate design of dies for profile extrusion applications. Prediction of extrudate swell has been challenging due to (i) difficulties associated with accurate representation of the constitutive behavior of polymer melts, and (ii) difficulties associated with the simulation of free surfaces, which requires special techniques in the traditionally used Eulerian framework. In a previous work we had argued that an Arbitrary Lagrangian Eulerian (ALE) based finite element formulation may have advantages in simulating free surface deformations such as in extrudate swell. In the present work we reinforce this argument by comparing our ALE simulations with experimental data on the extrudate swell of commercial grades of linear polyethylene (LLDPE) and branched polyethylene (LDPE). Rheological behavior of the polymers was characterized in shear and uniaxial extensional deformations, and the data was modeled using either the Phan–Thien Tanner (PTT) model or the eXtended Pom–Pom (XPP) model. Additionally, flow birefringence and pressure drop measurements were done using a 10:1 contraction–expansion (CE) slit geometry in a MultiPass Rheometer. Simulated pressure drop and contours of the principal stress difference were compared with experimental data and were found to match well. This provided an independent test for the accuracy of the ALE code and the constitutive equations for simulating a processing-like flow. The polymers were extruded from long (L/D = 30) and short (L/D = 10) capillaries dies at 190 °C. ALE simulations were performed for the same extrusion conditions and the simulated extrudate swell showed good agreement with the experimental data.     

Numerical solution of the eXtended Pom-Pom model for viscoelastic free surface flows

In this paper we present a finite difference method for solving two-dimensional viscoelastic unsteady free surface flows governed by the single equation version of the eXtended Pom-Pom (XPP) model. The momentum equations are solved by a projection method which uncouples the velocity and pressure fields. We are interested in low Reynolds number flows and, to enhance the stability of the numerical method, an implicit technique for computing the pressure condition on the free surface is employed. This strategy is invoked to solve the governing equations within a Marker-and-Cell type approach while simultaneously calculating the correct normal stress condition on the free surface. The numerical code is validated by performing mesh refinement on a two-dimensional channel flow. Numerical results include an investigation of the influence of the parameters of the XPP equation on the extrudate swelling ratio and the simulation of the Barus effect for XPP fluids.     

纤维悬浮液搅拌流动的数值模拟

由于缺乏适当的本构方程，对纤维悬浮液流动的研究一直局限于纤维的牛顿流体悬浮液。本文采用ＭＵＣＭ模型对作者最近提出的纤维Ｏｌｄｒｏｙｄ－Ｂ流体悬浮液的本构方程作了改进，并对锚式桨搅拌槽的二维Ｏｌｄｒｏｙｄ－Ｂ流体和牛顿流体纤维悬浮液搅拌流动作了数值模拟。模拟的结果表明，本文所用的模型和方法能有效地抑制过大局部应力的影响并合理地处理流体的记忆效应。     

THREE-DIMENSIONAL EXTRUDATE SWELL: FORMULATION WITH THE STREAM TUBE METHOD AND NUMERICAL RESULTS FOR A NEWTONIAN FLUID

Stream tube analysis, already applied to two-dimensional extrudate swell problems involving rate and integral constitutive equations for incompressible fluids, is now considered in the problem of free surface determination in a three-dimensional flow situation. The method allows computation of the unknown free surface by considering only a ‘peripheral stream tube’ limited by the wall and the jet surface and an inner stream surface. Those boundary surfaces are determined by considering the conservation equations together with boundary condition equations, solved by the Levenberg/Marquatdt optimization algorithm. The method leads to a considerable reduction in the number of degrees of freedom and the storage area. As in a previous study in the two-dimensional case, singularity problems in the vicinity of the junction points between the wall and the free surface are avoided. However, the numerical method still allows evaluati on of stress peaks due to the singularity at the exit, as may be observed for results obtained with a Newtonian fluid in a duct of square cross-section.     

Practical comparison of differential viscoelastic constitutive equations in finite element analysis of planar 4:1 contraction flow

Finite element modeling of planar 4:1 contraction flow (isothermal incompressible and creeping) around a sharp entrance corner is performed for favored differential constitutive equations such as the Maxwell, Leonov, Giesekus, FENE-P, Larson, White-Metzner models and the Phan Thien-Tanner model of exponential and linear types. We have implemented the discrete elastic viscous stress splitting and streamline upwinding algorithms in the basic computational scheme in order to augment stability at high flow rate. For each constitutive model, we have obtained the upper limit of the Deborah number under which numerical convergence is guaranteed. All the computational results are analyzed according to consequences of mathematical analyses for constitutive equations from the viewpoint of stability. It is verified that in general the constitutive equations proven globally stable yield convergent numerical solutions for higher Deborah number flows. Therefore one can get solutions for relatively high Deborah number flows when the Leonov, the Phan Thien-Tanner, or the Giesekus constitutive equation is employed as the viscoelastic field equation. The close relationship of numerical convergence with mathematical stability of the model equations is also clearly demonstrated.     

Numerical simulation of the extrusion of strongly compressible Newtonian liquids

The axisymmetric and plane extrusion flows of a liquid foam are simulated assuming that the foam is a homogeneous compressible Newtonian fluid that slips along the walls. Compressibility effects are investigated using both a linear and an exponential equation of state. The numerical results confirm previous reports that the swelling of the extrudate decreases initially as the compressibility of the fluid is increased and then increases considerably. The latter increase is sharper in the case of the exponential equation of state. In the case of non-zero inertia, high compressibility was found to lead to a contraction of the extrudate after the initial expansion, similar to that observed experimentally with liquid foams and to decaying oscillations of the extrudate surface. The time-dependent calculations show that the oscillatory steady-state solutions are stable. These steady-state oscillatory solutions are not affected by the length of the extrudate region nor by the boundary condition along the wall.     

A simple model to predict extrudate swell of polystyrene and linear polyethylenes

In a previous paper (Guillet and Seriai, 1991) we derived a simple analytical expression which allows the prediction of extrudate swell of polystyrene in a wide range of residence time. This was done using the rubber-like elasticity theory and calculation of the elongational strain recovery of a Lodge fluid. The theoretical extrudate swell ratio mainly depends on the relaxation modulus, the extension ratio and the recoverable shear strain. The main advantage of this model is to provide good accuracy with short dies in a wide range of shear rate. In this paper, we examine the validity of the proposed equation with different contraction ratios at the die entrance (ECR) and its ability to predict extrudate swell of other commodity polymers such as polyethylenes.     

Extrudate swell of Boger fluids

Boger fluids are dilute polymer solutions exhibiting high elasticity at low apparent shear rates, which leads to high extrudate swell. Numerical simulations have been undertaken for the flow of three Boger fluids (including benchmark Fluid M1), obeying an integral constitutive equation of the K-BKZ type, capable of describing the behavior of dilute polymer solutions. Their rheology is well captured by the integral model. The flow simulations are performed for planar and axisymmetric geometries without or with gravity. The results provide the extrudate swell and the excess pressure losses (exit correction), as well as the shape and extent of the free surface. All these quantities increase rapidly and monotonically with increasing elasticity level measured by the stress ratio, S_R. It was found that the main reason for the high extrudate swelling is high normal stresses exhibited in shear flow (namely, the first normal-stress difference, N₁). Surprisingly, the elongational parameter of the model or a second normal-stress difference N₂ do not affect the results appreciably. Gravity serves to lower the swelling considerably, and makes the simulations easier and in overall agreement with previous experiments.     

基于格子Boltzmann两相模型的粘弹流体挤出胀大分析

挤出胀大的数值模拟是非牛顿流体研究中具有挑战性的问题．本文运用格子Boltzmann方法(LBM)分析Oldroyd-B和多阶松弛谱PTT粘弹流体的挤出胀大现象,采用颜色模型模拟出口处粘弹流体和空气的两相流动,通过重新标色获得两种流体的界面,并最终获得胀大的形状．Navier-Stokes方程和本构方程的求解采用双分布函数模型．将胀大的结果与解析解、实验解和单相自由面LBM结果进行了比较,发现格子Boltzmann两相模型结果与解析解和实验结果相吻合,相比于单相模型,收敛速度更快,解的稳定性更高．研究了流道尺寸对胀大率的影响,并对挤出胀大的内在机理进行了分析．     

On the steady solution of linear advection problems in steady recirculating flows

Numerical modelling of non-Newtonian flows typically involves the coupling between equations of motion characterized by an elliptic behaviour, and the fluid constitutive equation, which is an advection equation linked to the fluid history. In this paper we prove that linear steady advection problems in steady recirculating flows have only one solution when the kinematics differs from a rigid motion. We also give a numerical procedure to determine this steady solution. We will describe this numerical procedure for two linear models the first will be the SFRT flow model and the second will be a simplified linear formulation of the Pom–Pom viscoelastic model.