Transient finite element analysis of generalized Newtonian coextrusion flows in complex geometries

A two-dimensional transient finite element model capable of simulating problems related to two-layer polymer flows has been developed. This technique represents an effective tool which can be used to study the possibility of the onset of interfacial instability in coextrusion flows, considering melt rheology as well as the fluid–geometry interaction. A code has been developed to solve the transient problem of the flow of bi-component systems of Newtonian and generalized Newtonian fluids through parallel plates and complex geometries, such as: 2:1 abrupt expansion, 2:1 (30°) expansion, 4:1 abrupt contraction and 4:1 tapered (30°) contraction. Solutions are compared with experimental data from the literature and results provided by linear stability analysis (LSA) for the case of parallel plate flows. Numerical results are in agreement with LSA results for the parallel plate geometry cases studied. The expansion geometries tend to stabilize flows in the parallel plate section downstream of the expansion. Contractions may give rise to break-up of the interface depending on the flow conditions. © 1998 John Wiley & Sons, Ltd.