Transient solutions of the dynamics in low-speed fiber spinning process accompanied by flow-induced crystallization

The transient solutions of the fiber spinning process when flow-induced crystallization occurs on the spinline have not been reported yet in the literature. By contrast, the steady state behavior is well understood and has been simulated by many researchers, as has the transient behavior with no crystallization on the spinline. In this study, this particular issue has been investigated in the low-speed spinning case where no necklike deformation occurs on the spinline, incorporating flow-induced crystallization into the mathematical model of the system and then devising proper numerical schemes to produce temporal pictures of fiber spinning process. It turns out that the difficulty in obtaining transient solution for fiber spinning when it is accompanied by flow-induced crystallization lies in the extreme sensitivity of the spinline velocity toward the fluid stress level. This parameter plays a key role in finding the spinneret stress level for the numerical marching scheme employed in obtaining the solutions of the governing equations. This is in sharp contrast to the case of no crystallization on the spinline where the profiles of spinline variables are almost insensitive to the spinneret stress level, thus allowing previous researchers to obtain transient solutions with little difficulty. In addition to the successful transient solutions of fiber spinning dynamics with flow-induced crystallization reported in the present study, it is also shown that the destabilizing effect of flow-induced crystallization in low speed spinning process is confirmed by a linear stability analysis.     

An experimental and theoretical study of the effect of the elongational history on the dynamics of isothermal melt spinning

Isothermal spinning of a low-density polyethylene (LDPE) melt has been compared with isothermal creep under a constant force. Although the same initial stress was applied in both measurements, there was a tremendous difference in the stretch ratio vs. time curves, which demonstrates the enormous effect the flow before and in the capillary has on the rheological behaviour of a polymer melt.The modelling of the upstream flow as a plug flow with velocity inversely proportional to the square of the channel radius has been the basis of the development of a computer program incorporating the effect of the prehistory on the velocity profile during spinning. The constitutive equation used was a well tested, single integral constitutive equation containing a memory function and a nonlinearity function. The calculated results have been compared with isothermal spinning data for various boundary conditions. The agreement between calculation and experiment is encouraging and indicates the importance of the elongational component in the upstream flow.     

High-speed fiber spinning process with spinline flow-induced crystallization and neck-like deformation

The dynamics and stability of the high-speed fiber spinning process with spinline flow-induced crystallization and neck-like deformation have been studied using a simulation model equipped with governing equations of continuity, motion, energy, and crystallinity, along with the Phan-Thien–Tanner constitutive equation. Despite the fact that a simple one-phase model was incorporated into the governing equations to describe the spinline crystallinity, as opposed to the best-known two-phase model [Doufas et al. J Non-Newton Fluid Mech, 92:27–66, 2000a]; [Kohler et al. J Macromol Sci Phys, 44:185–202, 2005] that treats amorphous and crystalline phases separately in computing the spinline stress, the simulation has successfully portrayed the typical nonlinear characteristic of the high-speed spinning process called neck-like spinline deformation. It has been found that the criterion for the neck-like deformation to occur on the spinline is for the extensional viscosity to decrease on the spinline, so that the spinning is stabilized by the formation of the spinline neck-like deformation. The accompanying linear stability analysis explains this stabilizing effect of the spinline neck-like deformation, corroborating a recent experimental finding [Takarada et al. Int Polym Process, 19:380–387, 2004].This paper was presented at the 2nd Annual European Rheology Conference 2005 on April 21–23, 2005, in Grenoble, France.     

Non-isothermal analysis of extrusion film casting using multi-mode Phan-Thien Tanner constitutive equation and comparison with experiments

Extrusion film casting (EFC) is an industrially important process which produces thousands of tons of polymer films, sheets, and coating used for various industrial as well as household applications. In this paper, we focus on an instability which occurs during certain polymer processing operations operating under predominantly elongational flow, such as extrusion film casting and fiber spinning. This instability, called the draw resonance, occurs in the form of sustained periodic fluctuations in the film dimensions. It appears when the process goes beyond the critical line speed of the EFC process. In this work, a conventional linear stability analysis is carried out for nonisothermal EFC process to determine the onset of the draw resonance. The polymer rheology is modeled by the Phan-Thien Tanner (PTT) multi-mode constitutive equation. For the implementation, a conventional shooting method approach is used. Extrusion film casting experiments were also carried out using a conventional linear low-density polyethylene (LLDPE) by varying process parameters such as draw ratio and aspect ratio, to observe the effect on the stability of the process. Linear stability analysis results under non-isothermal conditions are compared and validated with existing results from literature and with our own experimental data. This work displays the effect of multiple relaxation modes as well as the temperature influence on the stability of EFC process. Finally, results also indicate that the temperature highly affects the stability of the EFC process and cannot be ignored from modeling of EFC process.     

Systems analysis of hybrid, multi-scale complex flow simulations using Newton-GMRES

We present a methodology to analyze the stationary states and stability of complex fluid flows by using hybrid, discrete, and/or continuum multi-scale simulations. Building on existing theories, our scheme extracts dynamical and equilibrium characteristics from carefully chosen time integrations of these multi-scale evolution equations. Two canonical problems are presented to demonstrate the ability and accuracy of the formalism. The first is an investigation of flow-induced transitions seen in homogeneous, hard- rod liquid crystal suspensions subjected to a linear shear flow. In the second problem, we study the phenomenon of draw resonance, a dynamical instability in an isothermal fiber-spinning process, by using a multi-scale hybrid simulation that incorporates both stochastic and continuum models.     

Extensional rheology of concentrated poly(ethylene oxide) solutions

The shear and extensional rheology of three concentrated poly(ethylene oxide) solutions is examined. Shear theology including steady shear viscosity, normal stress difference and linear viscoelastic material functions all collapse onto master curves independent of concentration and temperature. Extensional flow experiments are performed in fiber spinning and opposed nozzles geometries. The concentration dependence of extensional behavior measured using both techniques is presented. The zero-shear viscosity and apparent extensional viscosities measured with both extensional rheometers exhibit a power law dependence with polymer concentration. Strain hardening in the fiber spinning device is found to be of similar magnitude for all test fluids, irrespective of strain rate. The opposed nozzle device measures an apparent extensional viscosity which is one order of magnitude smaller than the value determined with the fiber spinline device. This could be attributed to errors caused by shear, dynamic pressure, and the relatively small strains developed in the opposed nozzle device. This instrument cannot measure local kinematics or stresses, but averages these values over the non-homogenous flow field. These results show that it is not possible to measure the extensional viscosity of non-Newtonian and shear thinning fluids with this device. Fiber spin-line experiments are coupled with a momentum balance and constitutive model to predict stress growth and diameter profiles. A one-mode Giesekus model accurately captures the plateau values of steady and dynamic shear properties, but fails to capture the gradual shear thinning of viscosity. Giesekus model parameters determined from shear rheology are not capable of quantitatively predicting fiber spinline kinematics. However, model parameters fit to a single spinline experiment accurately predict stress growth behavior for different applied spinline tensions.     

Nonisothermal model of glass fiber drawing stability

Draw resonance is caused by a constant speed winder that leads to non-constant axial forces (Schultz, 1984). The well studied isothermal Newtonian fiber drawing predicts very modest critical draw ratios (around 20, much less than the typical production draw ratios for glass fibers of 10³ – 10⁵). The nonisothermal fiber drawing model presented here shows that cooling along the spin line strongly stabilizes the process. However, we show that the conclusion of Shah and Pearson (1972a,b) that non-isothermal Newtonian fiber spinning is unconditionally stable is based on non-converged numerical results. The choice of viscosity-temperature correlation function has a strong influence in determining the stability of the process. While viscoelasticity generally has an adverse effect on the stability, low viscoelasticity in the presence of extensional thinning helps to slightly improve the maximum critical draw ratio.Dedicated to the memory of Professor Tasos C. Papanastasiou     

Stretching flow instabilities at the exits of extrusion dies

As liquid leaves an extrusion die, the surface layers are rapidly stretched. Stretching flows may become unstable in two ways: by breaking, or in a ductile manner producing an uneven “necked” sample which, in continuous extrusion and drawing, is sometimes called “draw resonance”. There is a quantitative correlation between the extrusion defect known as “sharkskin” and the cohesive failure of polymer melts. By extruding under closely defined conditions, it is possible to introduce a transitory “structure” into the surface layer of the extrudate greatly enhancing its cohesive strength and eliminating this defect. A similar quantitative correlation is established between the uneven coating thickness sometimes obtained during coextrusion of a high viscosity melt on the surface of a low viscosity melt and the tensile drawing instability known as “draw resonance”. Simple criteria are established to avoid this problem in practical flow engineering.     

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.     

Draw resonance in film casting of viscoelastic fluids: A linear stability analysis

In order to understand the role of viscoelasticity on draw resonance in the isothermal film casting process, a steady state analysis and a linear stability analysis for three-dimensional flow disturbances have been conducted. The constitutive equation used is a modified convected Maxwell model, with shear-rate dependent viscosity and fluid characteristic time. The numerical results indicate that the flow is stable below a lower critical draw ratio and above an upper critical draw ratio. Shear thinning in viscosity reduces the lower critical draw ratio and somewhat increases the upper critical draw ratio—thereby enlarging the region of instability. Slower shear reduction in fluid characteristic time dramatically decreases the upper critical draw ratio but has no significant effect on the lower critical draw ratio; therefore, fluids with higher characteristic time are more stable.     

Multilayer film casting of modified Giesekus fluids Part 2. Linear stability analysis

A linear stability analysis of the multilayer film casting of polymeric fluids has been conducted. A modified Giesekus model was used to characterize the rheological behaviors of the fluids. The critical draw ratio at the onset of draw resonance was found to depend on the elongational and shear viscosities of the fluids. Extensional-thickening has a stabilizing effect, whereas shear-thinning and extensional-thinning have destabilizing effects. The critical draw ratios for bilayer films of various thickness fractions are bounded by those for single layer films of the two fluids. When the two fluids have a comparable elongational viscosity, the critical draw ratio at a given Deborah number varies linearly with thickness fraction. When one fluid has a much larger elongational viscosity, it dominates the flow and the critical draw ratios at most thickness fractions remain close to its critical draw ratio as a single layer film. When the dominating fluid exhibits extensional-thickening, a film with a certain thickness fraction has more than one critical draw ratio at a given Deborah number and may not exhibit draw resonance within some range of the Deborah number.     

Isothermal elongational behavior of liquid-crystalline polymers and LCPs based blends

The rheological behavior of two flexible thermoplastics, Nylon-6 (Ny) and bisphenol-A polysulfone (PSu), and two wholly aromatic liquid crystalline polymers, Vectra-A900 (VA) and Vectra-B950 (VB), as well as that of Ny/VB and PSu/VA blends with 10% LCP, has been investigated by the use of capillary viscometers equipped with cylindrical dies having different length-to-diameter ratios. The elongational viscosity of all materials was calculated, from the results of isothermal measurements carried out at 290°C, by means of the Cogswell's analysis, based on the estimation of the pressure drop due to the converging flow at the die inlet. The behavior in elongational flow was compared with the rheological behavior in shear flow conditions. It was found that the elongational viscosities of VA and VB are very large and account for a fairly marked pressure drop at the die entrance, due to the orientation of the LCP domains taking place in the converging flow zone. For these materials, the ratio of the elongational viscosity to the Newtonian shear viscosity is up to two orders of magnitude higher than the value expected on the basis of the Trouton rule. For the flexible resins, the Trouton ratio is 3 and ca. 3–10, are common values for high molar mass linear polymers. The addition of 10% LCP into the flexible resins strongly increases their elongational viscosity and makes the blends resemble neat LCPs in their extensional flow behavior. In shear flow, on the contrary, the addition of LCP was shown to induce a marked reduction of the melt viscosity, even when, as for the Ny/VB blend, the LCP is more viscous than the matrix.     

Thermal instabilities in melt spinning of viscoelastic fibers

Nonisothermal melt spinning of viscoelastic fibers for which the viscosity varies in a step-like manner with respect to temperature is studied in this work. A set of one-dimensional equations based on the slender-jet approximation and the upper convected Maxwell model is used to describe the melt spinning process. The process is characterized by the force required to pull the fiber, the strength of external heating, and the draw ratio, the square of the ratio of the fiber diameter at the spinneret to that at the take-up roller. For low levels of elasticity and sufficiently strong external heating, there can be three pulling forces consistent with the same draw ratio, similar to the Newtonian case studied by Wylie et al. [31]. For higher levels of elasticity, the process exhibits a draw ratio plateau where the draw ratio hardly changes with the pulling force, reflecting a competition between thermal and elastic effects. As in the Newtonian case, external heating introduces a new instability – termed thermal instability – that is absent in isothermal systems. Linear stability analysis reveals that external heating improves stability for low levels of elasticity, but can worsen stability for higher levels of elasticity, which is again a consequence of the interplay between thermal and elastic effects. Nonlinear simulations indicate that the predictions of linear stability analysis carry over to the nonlinear regime, and show that unstable systems exhibit limit-cycle behavior. The results of the present work demonstrate a possible mechanism through which external heating can stabilize the melt spinning of viscoelastic fibers.     

Enhanced melt strength and stretching of linear low-density polyethylene extruded under strong slip conditions

The influence of extrusion under strong slip conditions on the extensional properties of linear low-density polyethylene was studied in this work. The material was extruded at two different temperatures under strong slip and no slip conditions, and was subsequently subjected to uniaxial elongational flow by means of a Rheotens device. Strong slip was evident through the elimination of sharkskin distortions and the stick-slip instability, as well as by the electrification of the extrudates. The extrudate swell was smaller in the presence of slip when comparing with no slip conditions at constant apparent shear rate, but it was found to be a unique function of the shear stress if comparison was performed at constant stress. The draw ratio and melt strength of the filaments obtained under slip conditions were larger compared to those without slip. In addition, draw resonance was postponed to higher draw ratios during the extrusion with strong slip at constant apparent shear rate. It is suggested that slip of the polymer at the die wall decreases the shear stress in the bulk, and therefore, restricts the disentanglement and orientation of macromolecules during flow, which subsequently produces the increase in draw ratio and melt strength during stretching.     

Dynamical regimes of fiber spinning

An analytical solution is obtained that describes fiber spinning with a given force on the receiving bobbin. As an example, a calculation is made of the response of the final fiber section to a periodically varying draw force; a solution is constructed that describes the propagation along the fiber of a finite perturbation associated with a change in the conditions at the spinneret for a fixed draw force. The problem of the small perturbations of a fiber spun at a given rate onto a bobbin is reduced to a linear integrodifferential equation with retardation whose characteristic equation determines the region of the “draw resonance” instability. The reasons for the occurrence for the instability are elucidated.     

Nonlinear instability during the isothermal draw of optical fibers

The nonlinear instability of the isothermal draw of optical fibers from cylindric preforms is studied. The unsteady model of the process is solved numerically, accounting for the effects of inertia, gravity and surface forces. The effect of viscosity and gravity on the nonlinear stability of the process is studied. The possibility of draw resonance occurring is shown for a rate ratio much lower than the critical one, obtained when solving the simplified model. The proposed solution can be used to study technological stability and to model the draw of fibers of other materials which behave as Newtonian fluids.     

Estimates of apparent elongational viscosity using the fibre spinning and “pure” methods

A comparison is made between elongational properties predicted by the FENE-P dumbbell rheological equation of state for fibre spinning and true values obtained from pure elongation. True values are found by using a constant elongation rate in the model and calculating the steady state values of the stresses. Two new averaging procedures are suggested for extracting elongational properties from fibre spinning experiments. It is suggested that a variety of flow conditions be used and care be taken when determining these properties. The rheological model is found to predict adequately shear and elongational flow properties of the polyacrylamide-type of Boger or ideal elastic fluid.     

Numerical Flow Simulation for Bingham Plastics in a Single-Screw Extruder

Numerical simulations have been performed concerning the operation of a single-screw extruder, pumping a Bingham plastic under isothermal, developed flow conditions. Under the assumption of sufficiently low Reynolds numbers, inertia effects are neglected. The singular rheological behavior of the Bingham plastic is considered as the limiting case within a class of generalized Newtonian liquids with smooth constitutive equations. The validation of this regularization process is shown for a related flow problem where the Bingham solution is known analytically. A mixed finite-element method is applied to the flow in the screw-extruder to reduce the equations of motion, the continuity equation, and the regularized constitutive equation to a set of nonlinear algebraic equations, which are solved using a Newton method. In particular, the pumping characteristics of a given screw geometry are extracted from the finite-element calculations, i.e., the dependence of the volumetric flow rate and of the power requirement on the axial pressure drop, on the screw speed, and on the rheological parameters. Calculated flow fields clearly show the size and position of regions in the extruder channel where the Bingham plastic behaves like a solid. Received: 12 December 1995 and accepted 12 November 1996     

Determination of the elongational viscosity of polymer melts by melt spinning experiments. A comparison with different experimental techniques

In this work, melt spinning experiments were tentatively used for the determination of the elongational viscosity of polymer melts at different levels of tensile strain and strain rate. The materials examined were two high-density polyethylene grades for blow moulding with similar number-average molecular mass but different polydispersity index. The data from melt spinning tests were compared with transient extensional viscosity data obtained by uniform isothermal tensile tests, performed by means of an extensional rheometer, as well as with those produced by converging flow tests (Cogswell model). The results showed that for high strain and strain rate levels, the melt spinning experiments provide elongational viscosity data quite close to the transient extensional viscosity values obtained from the tensile tests.