Modeling flow induced crystallization in film casting of polypropylene

Data from iPP film casting experiments served as a basis to model the effect of flow on polymer crystallization kinetics. These data describe the temperature, width, velocity and crystallinity distributions along the drawing direction under conditions permitting crystallization along the draw length.In order to model the effect of flow on crystallization kinetics, a modification of a previously defined quiescent kinetic model was adopted. This modification consisted in using a higher melting temperature than in the original quiescent model. The reason for the modification was to account for an increase of crystallization temperature due to entropy decrease of the flowing melt. This entropy decrease was calculated from the molecular orientation on the basis of rubber elasticity theory applied to the entangled and elongated melt. The evolution of molecular orientation (elongation) during the film casting experiments was calculated using a non-linear dumbbell model which considers the relaxation time, obtained from normal stress difference and viscosity functions, to be a function of the deformation rate.The comparison between experimental distributions and model based crystallinity distributions was satisfactory.     

Effect of the rate of deformation on the crystallization behavior of polymers

Deformation has a significant influence on the crystallization process in a number of polymers. In this paper, the response of a recently developed model for crystallizing polymers is investigated when subject to uni-, bi-axial and constant width extensions for a range of strain rates. Both the loading and unloading behavior are examined for these deformations. The particular model studied here was developed to capture the effect of strain induced crystallization in polymers and has been applied to model crystallization in polyethylene terephthalate at temperatures just above its glass transition temperature. The model has been formulated using the notion of multiple natural configurations within a full thermodynamic framework. The connection between micro-structural changes taking place in the polymer and the form of the model are elucidated. The interplay between the relaxation processes, the rate of deformation and their combined effect on crystallization is illustrated. The results show an earlier onset of crystallization for high strain rates due to stretching of the polymer network. At low strain rates however, crystallization is not observed as the polymer network is able to relax during the deformation. A sharp upturn in the stress is observed after the onset of crystallization due to the formation of a rigid crystalline phase. The unloading curves clearly show a hysteric behavior with the amount of dissipation increasing for increasing values of strain rate. These results compare favorably with experimental observations available in literature.     

Modeling morphology evolution and mechanical behavior during thermo-mechanical processing of semi-crystalline polymers

A new model is proposed that combines statistical mechanics and thermodynamic aspects to characterize orientation development, nucleation and growth of crystallites, and chain entanglement slippage with interdependent relationships necessary to accurately correlate and in some cases predict the morphology and mechanical behavior of semi-crystalline polymers during various thermo-mechanical processes in the rubbery state, close to the glass transition temperature. Internal state variables (ISVs) that directly represent the underlying microstructure state are used to characterize polymer morphology and the resulting properties throughout deformation. The model uses fundamental thermodynamic coefficients for polyethylene terephthalate (PET) and is correlated to experimental data at various strain rates and temperatures just above the glass transition temperature. Experimental data are used that measure the stress, amorphous orientation, and crystallinity during uniaxial deformation of PET. The model is found to correlate well to these experimental data.     

Rheooptical study of the early stages of flow enhanced crystallization in isotactic polypropylene

The effect of a shear flow on the early stages and the kinetics of isothermal crystallization of an isotactic polypropylene has been studied experimentally. In the shear rate region where crystallization proceeds through point-like precursors, the magnitude of the shear rate, the shearing time as well as the instant in time at which the deformation starts have all been varied, in combination with rheooptical measurements. These include depolarized light intensity and birefringence. In agreement with previous work, above a critical shear rate and a critical shearing time, the crystallization kinetics are enhanced. Somewhat surprisingly, below a characteristic time, t_0,max, the kinetics are not affected by the instant in time at which flow is applied or stops. As long as flow takes place before this critical dwell time, only the shearing time and primarily the magnitude of the shear rate seem to matter. When flow is started only after t_0,max, its effect to accelerate crystallization kinetics becomes less efficient. The range over which the different parameters have an effect have been compared to the rheological relaxation times and to the measurements of global chain extension. To investigate the effects of flow on the early stages in more detail, time resolved Small-Angle Light Scattering experiments were used to detect changes in the density and orientation fluctuations. Measurements explicitly compare the effect of temperature and shear flow on the kinetics and the intensity of the density fluctuations.Electronic supplementary material to this paper can be obtained by using the Springer Link server located at     

Generalized Rouse model for a dilute solution of clustered polymers

A theory analogue to tha of Rouse is given, to describe the rheological behavior of dilute solutions consisting of clusters of crosslinked polymers. The frequency-dependent behavior of the dynamic moduli of these fluids differs substantially from that of the well-known Rouse-like fluid (GG^1/2). In our case the storage modulus becomes proportional to ^3/2, while the loss modulus is proportional to . The loss modulus dominates the dynamic behavior for frequencies smaller than the largest normal frequency of the clusters.     

Modeling a nonlinear process using the exponential autoregressive time series model

Nonlinear Dynamics - The parameter estimation methods for the nonlinear exponential autoregressive (ExpAR) model are investigated in this work. Combining the hierarchical identification principle...     

Thermal analysis of the roll in the strip casting process

Coiled strip can be directly produced through the twin-roll strip casting process from the melt by incorporating casting and hot rolling together into a single step. In this unique process, the strip formation from the molten metal critically relies upon the casting rolls. Thus, the design of the rolls is extremely essential. The coupled heat transfer and deformation analysis of the casting roll is carried out in a two-dimensional numerical model, using a finite element program (MARC) to examine the thermal stress and displacement. The effects of several factors such as the nickel overlay thickness on the roll surface, the casting speed, and the roll diameter on thermal characteristics are investigated.     

Pure steam condensation model with laminar film in a vertical tube

A new physical model for calculating the liquid film thickness and condensation heat transfer coefficient in a vertical condenser tube is proposed by considering the effects of gravity, liquid viscosity, and vapor flow in the core region of the flow. To estimate the velocity profile in the liquid film, the liquid film was assumed to be in Couette flow forced by the interfacial velocity at the liquid–vapor interface. For simplifying the calculation procedures, the interfacial velocity was estimated by introducing an empirical power-law velocity profile. The resulting film thickness and heat transfer coefficient from the model were compared with the experimental data and the results obtained from the other condensation models. The results demonstrated that the proposed model described the liquid film thinning effect by the vapor shear flow and predicted the condensation heat transfer coefficient from experiments reasonably well.     

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.     

Deformation of melts of mixtures of incompatible polymers in a uniform shear field and the process of their fibrillation

Fibril formation in mixtures of incompatible polymers, in this case polyethylene and polystyrene, has been studied with their melt being deformed in a uniform shear field. It has been found that when polyethylene is present in a smaller amount, it may form very long fibrils 5 to 8 μm in diameter in the deformed mixture. The formation of such fibrils is determined by the relationship between the viscosity ratio of the mixture components and shear stress. Also, just as in the case of a nonuniform shear field in a flow through a duct, fibril formation in melts of mixtures of incompatible polymers in a uniform shear field takes place upon reaching a certain shear stress. The lower the ratio between the viscosities of the fibril-forming polymer and the other component, the lower this shear stress.     

Theoretical development and experimental validation of a thermally dissipative cohesive zone model for dynamic fracture of amorphous polymers

A thermally dissipative cohesive zone model is developed for predicting the temperature increase at the tip of a crack propagating dynamically in a nominally brittle material exhibiting a cohesive-type failure such as crazing. The model assumes that fracture energy supplied to the crack tip region that is in excess of that needed for the creation of new free surfaces during crack advance is converted to heat within the cohesive zone. Bulk dissipation mechanisms, such as plasticity, are not accounted for. Several cohesive traction laws are examined, and the model is then used to make predictions of crack tip heating at various crack propagation speeds in the nominally brittle amorphous polymer PMMA, observed to fail by a crazing-type mechanism. The heating predictions are compared to experimental data where the temperature field surrounding a high speed crack in PMMA was measured. Measurements are made in real time using a multi-point high speed HgCdTe infrared radiation detector array. At the same time as temperature, simultaneous measurement of fracture energy is made by a strain gauge technique, and crack tip speed is monitored through a resistance ladder method. Material strength can be estimated through uniaxial tension tests, thus minimizing the need for parameter fitting in the stress-opening traction law. Excellent agreement between experiments and theory is found for two of the cohesive traction law temperature predictions, but only for the case where a single craze is active during the dynamic fracture of PMMA, i.e. crack tip speed up to approximately 0.2c_R. For higher speed fracture where subsurface damage becomes prominent, the line dissipation model of a cohesive zone is inadequate, and a distributed damage model is needed.     

Use of experiment and an inverse method to study interface heat transfer during solidification in the investment casting process

A technique to determine the thermal boundary conditions existing during the solidification of metallic alloys in the investment casting process is presented. Quantitative information about these conditions is needed so that numerical models of heat transfer in this process produce accurate results. In particular, the variation of the boundary conditions both spatially and temporally must be known. The method used involves the application of a new inverse heat conduction method to thermal data recorded during laboratory experiments of aluminium alloy solidification in investment casting shell moulds. The resultant heat transfer coefficient for the alloy/mould interface is calculated. An experimental programme to determine requisite mould thermal properties was also undertaken. It was observed that there is significant variation of the alloy/mould heat transfer coefficient during solidification. It is found to be highly dependent on the alloy type and on the vertical position below the initial free surface of the liquid metal. The aluminium casting alloys used in this study were 413, A356, 319 (Aluminum Association designations), and commercially pure aluminium. These alloys have significantly different freezing ranges. In particular, it was found that alloys with a high freezing range solidify with rates of heat transfer to the mould which are very sensitive to metallostatic head.     

A viscoelastic fluid model for describing the mechanics of a coarse ligated plasma clot

Thrombi are formed at the end of a series of complex biochemical processes. There are various types of thrombi, and their rheological properties change depending on the conditions during clot formation. In this paper, a model for a particular type of clot, formed from human plasma, is proposed within a thermodynamic framework that recognizes that viscoelastic fluids possess multiple natural configurations.     

An evaluation of the Larson-Doi model for liquid crystalline polymers using recoil

The mesoscopic models for the rheological properties of liquid crystalline polymers proposed by Larson and Doi in 1991 and Kawaguchi and Denn in 1999 are based on phenomenological expressions that describe the evolution of the defect density and the contribution of the “texture” to the stress. In the present work, we attempt to assess some of these assumptions by monitoring how the energy stored in the texture of liquid crystalline materials evolves during shear flows. For that purpose, strain recovery is measured as a function of the applied strain for flow reversal and intermittent flow. Solutions of poly-benzylglutamate in m-cresol, hydroxypropylcellulose in water and a nematic surfactant solution are used as model systems. Although the behaviour is described qualitatively by the model, discrepancies between the predictions and the experiments are observed, especially when the shear history includes rest periods. Received: 14 July 1999 /Accepted: 30 August 1999     

An analytical model for the determination of stability boundaries in a natural circulation single-phase thermosyphon loop

In this paper, an extension of previous analyses of natural circulation in a simple single-phase loop is presented. Assuming more general correlations for the friction factor and the heat transfer coefficient, an analytical model describing the system is obtained and a parametric representation of its dynamic behaviour is achieved. On this basis, stability maps can be drawn. A preliminary validation of the analytical model has been carried out by using an independent program developed for the analysis of stability in natural circulation loops. The aim of the present work is to provide a simple analytical tool devoted to the stability analysis of a reference single-phase loop. This model can be applied in a relatively wide range of conditions and regimes to provide benchmark solutions for thermal-hydraulic codes and related nodalisations.     

Development and experimental validation of a continuum micromechanics model for the elasticity of wood

This contribution covers the development and validation of a microelastic model for wood, based on a four-step homogenization scheme. At a length scale of several tens of nanometers, hemicellulose, lignin, and water are intimately mixed, and build up a polymer (polycrystal-type) network. At a length scale of around one micron, fiberlike aggregates of crystalline and amorphous cellulose are embedded in an contiguous polymer matrix, constituting the so-called cell wall material. At a length scale of about one hundred microns, the material softwood is defined, comprising cylindrical pores (lumen) in the cell wall material of the preceding homogenization step. Finally, at a length scale of several millimeters, hardwood comprises larger cylindrical pores (vessels) embedded in the softwood-type material homogenized before. Model validation rests on statistically and physically independent experiments: The macroscopic stiffness values (of hardwood or softwood) predicted by the micromechanical model on the basis of tissue-independent (‘universal’) phase stiffness properties of hemicellulose, amorphous cellulose, crystalline cellulose, lignin, and water (experimental set I) for tissue-specific composition data (experimental set IIb) are compared to corresponding experimentally determined tissue-specific stiffness values (experimental set IIa).     

Onset of convection in a horizontal porous channel with uniform heat generation using a thermal nonequilibrium model

This paper considers the onset of free convection in a horizontal fluid-saturated porous layer with uniform heat generation. Attention is focused on cases where the fluid and solid phases are not in local thermal equilibrium, and where two energy equations describe the evolution of the temperature of each phase. Standard linearized stability theory is used to determine how the criterion for the onset of convection varies with the inter-phase heat transfer coefficient, H, and the porosity-modified thermal conductivity ratio, γ. We also present asymptotic solutions for small values of H. Excellent agreement is obtained between the asymptotic and the numerical results.     

Investigation of the stability of a corona discharge continuum model in the shortwave approximation

The stability of a negative corona discharge between two spherical electrodes the inner of which is a hydrodynamic source is investigated. A continuum discharge model consisting of equations for the electrons and positive and negative ions written with allowance for electrokinetic reactions and electrodynamic equations is used. The steady-state (undisturbed) solution of this electrohydrodynamic system of equations is found using numerical methods and its stability is analyzed in the shortwave approximation for various structural zones of the corona discharge, namely, the ionization zone, the zone of attachment of electrons to neutral molecules, and the unipolar charge zone (negative ion zone). The perturbation growth rates in these zones are determined. It is shown that in the ionization zone the corona discharge considered is unstable.