On the predictive/fitting capabilities of the advanced differential constitutive equations for branched LDPE melts

Predictive/fitting capabilities of the XPP, PTT–XPP and modified Leonov constitutive equations are compared in both steady as well as transient shear and uniaxial elongational flows using two, highly branched LDPE materials (Escorene LD165BW1 and Bralen RB0323). It has been found that even if all three tested models exhibit very good fitting capability for steady uniaxial extensional viscosity curve, their predicting capabilities may differ significantly for shear viscosity as well as first and second normal stress coefficients.     

On the predictive/fitting capabilities of the advanced differential constitutive equations for linear polyethylene melts

This contribution examines the capabilities of three differential constitutive models (XPP, PTT-XPP, and modified Leonov) in predicting rheological properties of two virtually linear polyethylene materials (HDPE Tipelin FS 450-26, mLLDPE Exact 0201) with specific attention to both steady as well as transient shear and uniaxial elongational flow situations. For each situation the (dis)advantages of the individual models are discussed and both, qualitative and quantitative model efficiency evaluation has been carried out.     

Melt rheology of long-chain-branched polypropylenes

Rheological properties of long-chain-branched isotactic polypropylene (PP) via copolymerization with a very small amount of nonconjugated α,ω-diene monomer using metallocene catalyst system in both linear and nonlinear regions were investigated, comparing with conventional linear and long-chain-branched PP modified at postreactor. Although comonomer incorporation was equal to 0.05 mol% or less, it caused high molecular weight, broad molecular weight distribution, and long-chain branching. A detailed study on the effect of diene incorporation on the polymer properties was conducted, comparing with modified PP in postreactor. Polymer chain microstructures were characterized by gel permeation chromatography with multiangle laser light scattering (MALLS), differential scanning calorimetry, and rheological means: dynamic viscoelasticity, step-strain, uniaxial elongational flow measurements, and large amplitude oscillatory shear. The PP, which incorporated a small amount of diene monomer, showed significantly improved viscoelastic behaviors. The diene-propylene copolymer containing long-chain branches showed extremely long relaxation mode under shear and outstanding viscosity increase under elongational flow, so-called strain hardening. The difference in microstructure of diene-propylene copolymer with modified PP with long-chain branches is investigated by MALLS and rheological characterizations.     

Rheological behaviour of nano-composites based on polyamide 6 under shear and elongational flow at high strain rates

In this work, the rheological behaviour of high molecular mass polyamide 6 (PA6)/organo-montmorillonite nano-composites, obtained via melt blending, was investigated under shear and extensional flow. Capillary rheometry was used for the measurement of high shear rate steady state shear viscosity and die entrance pressure losses; further, by the application of a converging flow method (Cogswell model) to these experimental results, elongational viscosity data were indirectly calculated. The extensional behaviour was directly investigated by means of melt spinning experiments, and data of apparent elongational viscosity were determined. The results evidenced that the presence of the organo-clay in filled PA6 melts modifies the rheological behaviour of the material, with respect to the unfilled polymer, in dependence on the type of flow experienced by the fluid. In shear flow, the nano-composites showed a slightly lower viscosity than neat PA6, whereas in elongation, they appeared much more viscous, in dependence on the organo-clay content.     

Numerical simulation of entry flow of the IUPAC-LDPE melt

Numerical simulations have been undertaken for the creeping entry flow of a well-characterized polymer melt (IUPAC-LDPE) in a 4:1 axisymmetric and a 14:1 planar contraction. The fluid has been modeled using an integral constitutive equation of the K-BKZ type with a spectrum of relaxation times (Papanastasiou–Scriven–Macosko or PSM model). Numerical values for the constants appearing in the equation have been obtained from fitting shear viscosity and normal stress data as measured in shear and elongational data from uniaxial elongation experiments. The numerical solutions show that in the axisymmetric contraction the vortex in the reservoir first increases with increasing flow rate (or apparent shear rate), goes through a maximum and then decreases following the behavior of the uniaxial elongational viscosity. For the planar contraction, the vortex diminishes monotonically with increasing flow rate following the planar extensional viscosity. This kinematic behavior is not in agreement with recent experiments. The PSM strain-memory function of the model is then modified to account for strain-hardening in planar extension. Then the vortex pattern shows an increase in both axisymmetric and planar flows. The results for planar flow are compared with recent experiments showing the correct trend.     

Linear viscoelastic model for elongational viscosity by control theory

Flows involving different types of chain branches have been modelled as functions of the uniaxial elongation using the recently generated constitutive model and molecular dynamics for linear viscoelasticity of polymers. Previously control theory was applied to model the relationship between the relaxation modulus, dynamic and shear viscosity, transient flow effects, power law and Cox–Merz rule related to the molecular weight distribution (MWD) by melt calibration. Temperature dependences and dimensions of statistical chain tubes were also modelled. The present study investigated the elongational viscosity. We introduced earlier the rheologically effective distribution (RED), which relates very accurately and linearly to the viscoelastic properties. The newly introduced effective strain-hardening distribution (RED_H) is related to long-chain branching. This RED_H is converted to real long-chain branching distribution by melt calibration and a simple relation formula. The presented procedure is very effective at characterizing long-chain branches, and also provides information on their structure and distribution. Accurate simulations of the elongational viscosities of low-density polyethylene, linear low-density polyethylene and polypropylene, and new types of MWDs are presented. Models are presented for strain-hardening that includes the monotonic increase and overshoot effects. Since the correct behaviour at large Hencky strains is still unclear, these theoretical models may aid further research and measurements.     

Rheological characterisation of a high-density polyethylene with a multi-mode differential viscoelastic model and numerical simulation of transient elongational recovery experiments

The rheological characterisation of a high-density polyethylene is performed by means of measurements of the storage and loss moduli, the shear viscosity and the transient uniaxial elongational viscosity, the latter being obtained with the Meissner extensional rheometer. The rheological behaviour of the polymeric material is described by means of a multi-mode Phan Thien-Tanner fluid model, the parameters of which are successively fitted on the basis of the linear and non-linear properties. By using a semi-analytical technique and the finite element method, numerical investigations are performed for the shape recovery of the sample, and the predictions are compared with their experimental counterparts. Surface tension effects are also explored. We discuss the agreement between the experiments and the simulation results. Received: 15 October 1998 Accepted: 22 December 1998     

Rheological properties of electron beam-irradiated polypropylenes with different molar masses

Electron beam-irradiated polypropylene undergoes chain scission initiated by the loss of a proton. The resulting macroradicals can lead to branched molecules. However, the understanding of the influence of irradiation on the branching of polypropylene is still scarce. Therefore, this paper investigates structure?Cproperty relationships in such irradiated polymers. In general, irradiation yields long-chain branches, which develop from a star-like into a tree-like branching architecture with increasing dose. These conclusions can be drawn from the relation between the zero shear-rate viscosity ?? ₀ and the weight average molar mass M _w as well as from the elongational behavior.     

Measurements and model predictions of transient elongational rheology of polymeric nanocomposites

Transient elongational rheology of two commercial-grade polypropylene (PP) and the organoclay thermoplastic nanocomposites is investigated. A specifically designed fixture consisting of two drums (SER Universal Testing Platform) mounted on a TA Instruments ARES rotational rheometer was used to measure the transient uniaxial extensional viscosity of both polypropylene and nanoclay/PP melts. The Hencky strain rate was varied from 0.001 to 2 s^− 1, and the temperature was fixed at 180°C. The measurements show that the steady-state elongational viscosity was reached at the measured Hencky strains for the polymer and for the nanocomposites. The addition of nanoclay particles to the polymer melt was found to increase the elongation viscosity principally at low strain rates. For example, at a deformation rate of 0.3 s^− 1, the steady-state elongation viscosity for polypropylene was 1.4 × 10⁴ Pa s which was raised to 2.8 × 10⁴ and 4.5 × 10⁴ Pa s after addition of 0.5 and 1.5 vol.% nanoclay, respectively. A mesoscopic rheological model originally developed to predict the motion of ellipsoid particles in viscoelastic media was modified based on the recent developments by Eslami and Grmela (Rheol Acta 47:399–415, 2008) to take into account the polymer chain reptation. We show that the orientation states of the particles and the rheological behavior of the layered particles/thermoplastic hybrids can be quantitatively explained by the proposed model.     

Flow-induced crystallization of high-density polyethylene: the effects of shear and uniaxial extension

The effects of shear, uniaxial extension and temperature on the flow-induced crystallization of two different types of high-density polyethylene (a metallocene and a ZN-HDPE) are examined using rheometry. Shear and uniaxial extension experiments were performed at temperatures below and well above the peak melting point of the polyethylenes in order to characterize their flow-induced crystallization behavior at rates relevant to processing (elongational rates up to 30 s^− 1 and shear rates 1 to 1,000 s^− 1 depending on the application). Generally, strain and strain rate found to enhance crystallization in both shear and elongation. In particular, extensional flow was found to be a much stronger stimulus for polymer crystallization compared to shear. At temperatures well above the melting peak point (up to 25°C), polymer crystallized under elongational flow, while there was no sign of crystallization under simple shear. A modified Kolmogorov crystallization model (Kolmogorov, Bull Akad Sci USSR, Class Sci, Math Nat 1:355–359, 1937) proposed by Tanner and Qi (Chem Eng Sci 64:4576–4579, 2009) was used to describe the crystallization kinetics under both shear and elongational flow at different temperatures.     

A numerical study of constitutive models endowed with Pom-Pom molecular attributes

The branched polymer melts are modeled respectively in this investigation by the existing XPP and PTT–XPP models, along with the proposed S-MDCPP (Single/Simplified Modified Double Convected Pom-Pom) model developed on the basis of the existing MDCPP model. A pressure stabilized mass equation is formulated with the finite increment calculus (FIC) process to restrain and further eliminate spurious oscillations of pressure field due to the incompressibility of fluids. The discrete elastic viscous stress splitting (DEVSS) technique is employed, in order to retain an elliptic contribution in the weak form of the momentum equation. An inconsistent streamline-upwind (SU) method is applied to spatially discretize the constitutive equations. The mass, momentum conservation and constitutive equations are discretized and solved by the iterative stabilized fractional step algorithm along with the Crank–Nicolson implicit difference scheme. Thus the finite elements with equal low-order interpolation approximations for velocity–pressure–stress variables can be devised to numerically simulate the viscoelastic contraction flows for branched LDPE melts. The influences of the three viscoelastic constitutive models and the branched arms at the end of the Pom-Pom molecule on the rheological behaviors occurring in this complex flow are discussed. The numerical results demonstrate that the proposed S-MDCPP model is capable of reproducing some properties similar to those predicted by the XPP model in high shear flow and, on the other hand, reproducing some properties similar to those predicted by the PTT–XPP model in high elongational flow. Furthermore, the proposed S-MDCPP model is capable of well identifying the macromolecule topological structures of branched polymer melts.     

Prediction of steady-state viscous and elastic properties of polyolefin melts in shear and elongation

The linear and nonlinear steady-state viscosities and elastic compliances were measured in shear and elongational flows for two low-density polyethylenes, a linear polypropylene, and two metallocene catalyzed polyethylenes (one linear and one long-chain branched) by Wolff et al. (Rheol Acta 49:95?C103, 2010) and Resch (dissertation, 2010). Comprehensive data of this type are rarely found in the literature, and comprehensive modeling of both viscous and elastic effects is even rarer. In this contribution, the reliability of a modeling approach proposed by Laun (J Rheol 30(3):459?C501, 1986) and based on the damping function concept is tested. The strain hardening seen for the long-chain branched polymers and its absence in the case of the linear polymer, the stronger decrease of the tensile compliance in comparison to the shear compliance with increasing stress, as well as the extended linear-viscoelastic regime of the shear viscosity in contrast to the shear compliance are correctly modeled. While the modeling of the nonlinear response in shear can be achieved with only one material parameter for most of the polymers considered here, the nonlinear modeling in elongation is achieved with two parameters. The same parameter values are shown to describe viscous as well as elastic properties of the melts, and thus the relations of Laun can be used to test the consistency of viscosity and compliance measurements.     

On the “viscosity overshoot” during the uniaxial extension of a low density polyethylene

An experimental investigation of the viscosity overshoot phenomenon observed during uniaxial extension of a low density polyethylene is presented. For this purpose, traditional integral viscosity measurements on a Münstedt-type extensional rheometer are combined with local measurements based on the in-situ visualization of the sample under extension. For elongational experiments at constant strain rates within a wide range of Weissenberg numbers (Wi), three distinct deformation regimes are identified. Corresponding to low values of Wi (regime I), the tensile stress displays a broad maximum, but such maximum is observed with various polymeric materials deformed at low rates and it should not be confused with the “viscosity overshoot” phenomenon. Corresponding to intermediate values of Wi (regime II), a local maximum of the integral extensional viscosity is systematically observed. Moreover, within this regime, a strong discrepancy between integral measurements and the space average of the local elongational viscosity is observed which indicates large deviations from an ideal uniaxial deformation process. Images of samples within this regime reinforce this finding by showing that, corresponding to the maximum of the integral viscosity, secondary necks develop along the sample. The emergence of a maximum of the integral elongational viscosity is, thus, related to the distinct inhomogeneity of deformation states and most probably not to the rheological properties of the material. In the fast stretching limit (high Wi, regime III), the overall geometric uniformity of the sample is well preserved, no secondary necks are observed and both the integral and the space averaged transient elongational viscosity show no maximum. A detailed but yet incomplete comparison of the experimental findings with results from the literature is presented and several open questions are stated.     

Comparison of the melt fracture behavior of metallocene and conventional polyethylenes

The influence of sparse long-chain branching and molecular weight distribution on the melt fracture behavior of polyethylene melts was investigated. Four commercial polyethylene resins were employed for this study: a conventional low-density polyethylene, a conventional linear low-density polyethylene, a linear metallocene polyethylene, and a sparsely branched metallocene polyethylene. Rheological measurements were obtained for both shear and extensional deformations, and melt fracture experiments were carried out using a controlled rate capillary rheometer. A single capillary geometry was used to focus on the effects of material properties rather than geometric factors. For the linear polyethylenes, surface melt fracture, slip-stick fracture, and gross melt fracture were all observed. Conversely, the branched PE resins did not exhibit a slip-stick regime and the degree of gross fracture was observed to be much more severe than the linear resins. These variations can be explained by the effects that long-chain branching has on the onset of shear-thinning behavior (slip-stick fracture) and the degree of extensional strain hardening (gross melt fracture). Although there is some indication that the breadth of molecular weight distribution indirectly influences surface melt fracture, the results remain inconclusive.     

Bagley correction: the effect of contraction angle and its prediction

The excess pressure losses due to end effects (mainly entrance) in the capillary flow of a branched polypropylene melt were studied both experimentally and theoretically. These losses were first determined experimentally as a function of the contraction angle ranging from 10° to 150°. It was found that the excess pressure loss function decreases for the same apparent shear rate with increasing contraction angle from 10° to about 45°, and consequently slightly increases from 45° up to contraction angles of 150°. Numerical simulations using a multimode K-BKZ viscoelastic and a purely viscous (Cross) model were used to predict the end pressures. It was found that the numerical predictions do agree well with the experimental results for small contraction angles up to 30°. However, the numerical simulations under-predict the end pressure for larger contraction angles. The effects of viscoelasticity, shear, and elongation on the numerical predictions are also assessed in detail. Shear is the dominant factor controlling the overall pressure drop in flows through small contraction angles. Elongation becomes important at higher contraction angles (greater than 45°). It is demonstrated in abrupt contractions (angle of 180°) that both the entrance pressure loss and the vortex size are strongly dependent on the extensional viscosity for this branched polymer. It is suggested that such an experiment (visualisation of entrance flow) can be useful in evaluating the validity of constitutive equations and it can also be used to fitting parameters of rheological models that control the elongational viscosity.     

Investigation of the rheological properties of short glass fiber-filled polypropylene in extensional flow

The behavior of short glass fiber–polypropylene suspensions in extensional flow was investigated using three different commercial instruments: the SER wind-up drums geometry (Extensional Rheology System) with a strain-controlled rotational rheometer, a Meissner-type rheometer (RME), and the Rheotens. Results from uniaxial tensile testing have been compared with data previously obtained using a planar slit die with a hyperbolic entrance. The effect of three initial fiber orientations was investigated: planar random, fully aligned in the stretching flow direction and perpendicular to it. The elongational viscosity increased with fiber content and was larger for fibers initially oriented in the stretching direction. The behavior at low elongational rates showed differences among the various experimental setups, which are partly explained by preshearing history and nonhomogenous strain rates. However, at moderate and high rates, the results are comparable, and the behavior is strain thinning. Finally, a new constitutive equation for fibers suspended into a fluid obeying the Carreau model is used to predict the elongational viscosity, and the predictions are in good agreement with the experimental data.     

Rheological properties of long glass fiber filled polypropylene

Long glass fiber-filled polypropylene (PP) composites are produced by pultrusion, and the extrudate is cut at different lengths producing composites containing long fibers of controlled length. The rheological properties of such composites in the molten state have been studied using different rheometers. A capillary rheometer has been constructed and mounted on a molding-injection machine. The shear viscosity of filled PP determined from the capillary rheometer, after corrections for entrance effects, was found to be very close to that of unfilled PP. However, large excess pressure losses at the capillary entrance were observed and these data have been used to obtain an apparent elongational viscosity. The apparent elongational viscosity was shown to be considerably larger than the shear viscosity for PP and filled PP, and it increased markedly with fiber length and fiber content. Rotational rheometers with a parallel-plate geometry were used to investigate the viscoelastic properties of these composites and their behavior was found to be non-linear, exhibiting a yield stress. A model is proposed to describe the shear viscosity from a solid-like behavior at low stresses to fluid-like behavior at high shear stresses taking into account fiber content and orientation. A modified model, proposed for elongational flow, describes relatively well the apparent elongational data.     

Branched viscoelastic surfactant solutions and their response to elongational flow

Several years ago, Münstedt and Laun reported on the influence of branching on the elongational flow properties of polymer chains (Münstedt and Laun, 1981). They concluded that, in addition to the molecular weight distribution, the degree of branching strongly affects the degree of strain thickening of the elongational viscosity in such a way that the maximum in this material function increases with branching. In a recent paper by Lin, a ternary system of dodecyldimethylamine oxide-sodium laureth sulphate-sodium chloride surfactant solutions was investigated by CryoTEM and rheology (Lin, 1996). He reported a linear relation between the added sodium chloride and the branching of the wormlike micelles. In this paper we present an investigation of these surfactant solutions in elongational flow. Our results indicate that for branched micellar systems the presence of branching enhances the maximum of the elongational viscosity in the same manner as in the case of polymer melts.     

Extracting extensional properties through excess pressure drop estimation in axisymmetric contraction and expansion flows for constant shear viscosity,extension strain-hardening fluids

In this study, hyperbolic contraction–expansion flow (HCF) devices have been investigated with the specific aim of devising new experimental measuring systems for extensional rheological properties. To this end, a hyperbolic contraction–expansion configuration has been designed to minimize the influence of shear in the flow. Experiments have been conducted using well-characterized model fluids, alongside simulations using a viscoelastic White–Metzner/FENE-CR model and finite element/finite volume analysis. Here, the application of appropriate rheological models to reproduce quantitative pressure drop predictions for constant shear viscosity fluids has been investigated, in order to extract the relevant extensional properties for the various test fluids in question. Accordingly, experimental evaluation of the hyperbolic contraction–expansion configuration has shown rising corrected pressure drops with increasing elastic behaviour (De=0～16), evidence which has been corroborated through numerical prediction. Moreover, theoretical to predicted solution correspondence has been established between extensional viscosity and first normal stress difference. This leads to a practical means to measure extensional viscosity for elastic fluids, obtained through the derived pressure drop data in these HCF devices.     

Numerical simulation of contraction and expansion flows of Langmuir monolayers

Langmuir monolayers consist of amphiphilic molecules at the air–water interface and can be modeled as two-dimensional fluids. Earlier experiments [D.J. Olson, G.G. Fuller, J. Non-Newtonian Fluid Mech. 89 (2000) 187–207] on 4:1 contraction and 4:1 expansion flows have been simulated using an integral constitutive equation of the K-BKZ type, suitably modified to account for strain-thickening in the planar extensional viscosity. The model has been used to fit linear viscoelastic data (G′ and G″) and the shear viscosity (η_S), while the amount of strain-hardening is assumed, due to lack of experimental data. The simulations are in good agreement with the experiments on Newtonian monolayers, which show no vortices in the contraction but large inertial vortices in the expansion. For the viscoelastic monolayer (a poly-octadecyl methacrylate or PODMA), the opposite is true. The contraction flow shows vortices, while in the expansion flow the vortex activity is substantially reduced compared with the Newtonian one. The viscoelastic behavior is well captured by the model, provided that substantial strain-thickening is exhibited by the monolayer in planar extension. The latter behavior is very much like that for a branched LDPE melt, which also shows big vortices due to strain-hardening in planar as well as in uniaxial extension.