Professional Documents
Culture Documents
oyonnax 10/07/13
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ALPlastics
oyonnax 10/07/13
Outline
Polymer Processing : Challenges
Injection Moulding
Plastication in injection Moulding
Physics
Visualization
Modelling
Fibre breakage
Flow in screw channel
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ALPlastics
oyonnax 10/07/13
Thermo-Plastics Processing :
Heat transfer
solide
pellets, powder
Mechanics
melting
Challenges
liquid
aspect
solid
part
molten polymer
plastication
moulding
temperature, rpm
Tcryst., Tmould
geometry
mechanical properties
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oyonnax 10/07/13
Injection-Moulding
Cyclic Process : widely used for making thin parts (not hollow)
2 metering
3 injection
1 plastication
4 packing
6 cooling
5 holding
7 part ejection
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ALPlastics
oyonnax 10/07/13
Visualisation
Looking for a visualization device :
Scale relevant to polymer processing machines
Applicable to screw barrel units
continuous in line flow visualisation : 3D, no blind spots
Automated particle tracking ( particle : pellet, fibre, fluorescent tracer )
Post-treatment of position : Velocities
Literature review
Extruder with glass windows to observe solid bed motion and plasticising:
Wong (1999) [WLLZ99], Gao (2000) [GJC00].
Transparent barrel with (one or two ) video cameras to record a particle motion:
Campbell 1992 [CSF92], Choo 1980 [CNP80].
Magnetic Resonance Imaging (MRI) on a non-metallic barrel and screw unit :
Amin (2003) [AHH+ 03], Agemura (1995) [AKM95].
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oyonnax 10/07/13
camera V1
computer H
mobile rack
led
calibrator
usb
camera H2
clock
camera H1
particle
firewire
led
usb
computer V
Barrel : PMMA
barrel
camera V2
[Mog05]M. Moguedet. Dveloppement dun outil daide la conception et au fonctionnement dun ensemble vis/fourreau
industriel -Application linjection de thermoplastiques chargs fibres de verre longues. PhD thesis, INSA-Lyon, 12
Dcembre 2005
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ALPlastics
oyonnax 10/07/13
Particle moving down and up the channel : slow near the barrel fast near the screw root
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page 8
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[Pha13]T.-L. Pham. Plastification des polymres fonctionnels et chargs. PhD thesis, INSA-Lyon, 2013. en cours
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oyonnax 10/07/13
flow
flight
solid bed
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page 10
melt pool
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oyonnax 10/07/13
Plastication
hopper
pellets
solid bed
barrel
screw
rpm
nozzle
melt film
melt pool
Pellets melt along the screw following Maddock/Tadmor model : [Mad59, TDK67]
Solid bed of compacted pellets with continuously decreasing width
Molten polymer film at the barrel inner surface ...
... continuously wiped by the screw flights ...
accumulates in a melt pool
Unresolved issues :
solid bed permeability [NOF04], Solid bed velocity and acceleration, [FkSN82], lateral melt films
[Lin85]?
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ALPlastics
oyonnax 10/07/13
fourreau
=
mlt
Vbx
1111111111
0000000000
Vsy
0000000000
1111111111
0000000000
1111111111
0000000000
1111111111
Tm
0000000000
1111111111
X
0000000000
1111111111
0000000000
1111111111
0000000000vis
1111111111
KVrn+1 1n
Br =
km (Tb Tm )
a(T b Tm )
A =
n
BACK
Tm ) (1 + Br U1 ) X
Ethlpy
=
mlt
v
u
u Vbx U2 m km (Tb
t
mlt
=
m Vbx U2 (A)
d
(s HXVsz )
dz
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Plastication : Results
Solid fraction X/W along the screw length :
1
Feed
0.9
Metering
Transition
0.8
0.7
0.6
0.5
Pryltex
0.4
PP
0.3
HDPE
0.2
rpm 40
0.1
screw 90mm
Feed
0.9
10
12
N screw/turn
14
16
18
Metering
0.8
0.7
0.6
0.5
0.4
screw 90mm
0.3
0.2
0.1
Transition
Tb +50C
2
10
12
N screw/turn
14
16
18
Plastication length :
increases with shear rate (increase viscous dissipation) (at a given throughput)
decreases with higher screw rpm
higher barrel temperature conflicting : increases conduction but decreases viscosity
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ALPlastics
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Specifics :
not continuous (steady state) but cyclic
1
1
0,9
0,9
0,8
0,8
0,7
0,7
0,6
0,6
0,5
0,5
0,4
0,4
0,3
0,3
0,2
0,2
0,1
0,1
0
0
Injection
Extrusion
10
10
15
15
20
20
dwell : film thickness increases by transient con- [Apa05] R. E. Apaloo. Plastification en injection. simplast.
Masters thesis, Insa-Lyon, GMPP, 2005
duction
s
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km (Tb Tm )tdwell
+ 0
s
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Fibre Breakage
Fibres anchored at one end in solid bed, submitted at the other end to intense shear
Vbx
fourreau
111111
000000
0
1
d
000000000
111111111
000000
111111
0
1
000000000
111111111
000000
111111
0
1
00000000000000
11111111111111
000000000
111111111
000000
111111
00000000000000
11111111111111
000000
111111
00000000000000
11111111111111
00000000000000
11111111111111
lit solide
00000000000000
11111111111111
00000000000000vis
11111111111111
000000
0
1
111111
l
Z l
128 3n KVrn
An1
(1 exp(Ax))x
=
dx
d3
(exp(A) 1)n 0
log( 7.4
)
Re
depends on film thickness , shear rate, viscosity K, fibre diameter d and orientation l
Fibre breaks when applied > max
New layer of fibres uncovered as the solid bed is melting
Fibre length distribution obtained starting from a uniform distribution with random orientation
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ni L i
Ln = Pi
i ni
80
Lw exp = 3.85 mm
Lw calc = 3.60 mm
35
fraction en masse %
Ln,Lw (mm)
40
Ln exp
Ln calc
Lw exp
Lw calc
70
fraction en nombre %
10
ni L2i
Lw = P
i ni Li
P
30
25
20
15
Ln exp = 1.05 mm
Ln calc = 1.10 mm
60
50
40
30
10
20
10
10
N D_Vis
15
20
3 4 5 6 7 8
longueur fibre (mm)
3 4 5 6 7 8
longueur fibre (mm)
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Dcembre 2005
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ALPlastics
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Vx
N
V
Vz
z
W
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BackPressure
Screw Diameter
Hfeed
m
= m Qliq + s Vsz HX
Q?
rpm
Hmeter
Lfeed
Lcomp
Lmeter
m Q
1D relationship between flow rate and local pressure gradient for power-law fluids:
Q =
Vbz W H
|6G|s sgn(G)f ()
(1 + s)(1 + 2s)
G =
H n+1 (z) dP
6KV0n dz
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W X
W
HX
Halim Walim
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oyonnax 10/07/13
70
PS Styron, T 211C
PC Lexan, T 285C
60
30
pressure (MPa)
80
pressure (MPa)
90
100
20
35
30
20
50
15
10
rpm=40
10%
rpm=100
10
30
25
15
40
40
20
30
40
50
60
70
80
90
100
10
15
20
25
30
N screw turn
10
15
20
25
30
N screw turn
Throughput :
1. Screw geometry
2. Polymer Rheology
3. Plastication length
[BCM09] Y. Breaux, J.-Y. Charmeau, and M. Moguedet. A simple model of throughput and pressure development for
single screw. Journal of Material Technology and Processing, 209(1):611618, 2009
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Aims
Specific effects of helical geometry on flow of viscous and viscoelastic fluid
Hypotheses
Incompressible fluid in steady-state creeping flow
Screw channel :
constant depth and pitch
curvature, torsion
flights
rectangular cross-section
No leakage flow through barrel/screw clearance
Perturbation method
pressure & drag flow of viscous fluids
pressure flow of viscoelastic fluids
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ALPlastics
oyonnax 10/07/13
2P
W/2
B
R
H/2
Geometry
BACK
Dimensionless Numbers
Hydraulic Diameter
Curvature
Torsion
Helix Angle
tan()
2HW
H +W
R
2
R + P2
P
2
R + P2
P
R
page 22
W
H
tan()
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Applicability
6.9
21.8
Curvature
0.44
0.15
Torsion
0.16
0.05
0.36
0.33
tan()
Curvature and torsion are small but not negligible dimensionless parameters
Aspect ratios are very large
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Overview
Fluid
Flow type
Flow direction
Helicity
viscous
drag
down-channel w
curvature
viscoelastic
pressure
cross-channel u, v,
torsion
Ducts
y
Z
Z
y
Y
X
Tore ()
BACK
Helix (, )
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oyonnax 10/07/13
w0
=1
0.5
0.5
0.5
0.4
0.4
0.4
0.3
0.3
0.3
0.2
0.2
0.2
0.1
0.1
0.1
-0.4
-0.3
-0.2
-0.1
outer wall <---
0
x
0.1
0.2
--> inner wall
0.3
0.4
-0.1
-0.1
-0.2
-0.2
-0.2
-0.3
-0.3
-0.3
-0.4
-0.4
-0.4
-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall
-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall
0.5
0.5
0.5
0.4
0.4
0.4
0.3
0.3
0.3
0.2
0.2
0.2
0.1
0.1
-0.5
-0.1
-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall
= 1/5
w0 + w + 2 w2
0.1
y
-0.1
-0.1
-0.1
-0.2
-0.2
-0.2
-0.3
-0.3
-0.3
-0.4
-0.4
-0.4
-0.5
0.5
-0.5
0.5
-0.5
-0.4
-0.3
-0.2
-0.1
outer wall <---
0
x
0.1
0.2
--> inner wall
0.3
0.4
-0.5
-0.4
-0.3
-0.2
-0.1
outer wall <---
0
x
0.1
0.2
--> inner wall
0.3
0.4
-0.5
0.5
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2.5
1.5
w plfw, y = 0
1
w plfw, x = 0
w0 + w + 2 w2 , y = 0
w0 + w + 2 w2 , x = 0
w0 + w , y = 0
0.5
0
0.5
x, y
0.4
0.3
0.2
0.1
0.1
0.2
0.3
0.4
0.5
= 0.66, = 0, = 0.5
large shift of the down-channel velocity w towards the inner wall (deep channel)
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Cross-channel velocity u, v,
0.25
1.8
0.2
1.6
0.15
1.4
u/w0av
w/w0av
1.2
1
w0 + 2 w2 , y = 0
w0 + 2 w2 , x = 0
w0 , y = 0
w0 , x = 0
w plfw, y = 0
y
w plfw, x = 0
0.6
0.4
0.2
0
0.5
0.4
0.3
0.2
0.1
0.1
0.8
0.1
0.2
u plfw, y = 0.25
u , y = 0.25
u plfw, x = 0
u , x = 0
0.05
0
u plfw, x = 0.25
u , x = 0.25
0.05
0.1
0.15
0.2
0.3
0.4
0.5
0.25
0.5
x, y
0.4
0.3
0.2
0.1
0.1
0.2
0.3
0.4
x, y
= 2, = 0.6, = 0
= 5, = 0.15, = 0
Narrower w profile
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0.5
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
-0.2
-0.3
-0.5
0.1 0.2 0.3 0.4 0.5
0.4
0.3
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
-0.2
-0.3
0.3
0.2
0.4
0.2
-0.5
0.1 0.2 0.3 0.4 0.5
-0.4
-0.3
-0.2
-0.1
0 y
0.1
w0d GP w0
0.1
0 y
-0.1
-0.2
-0.3
-0.4
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BACK
oyonnax 10/07/13
ALPlastics
ALPlastics
oyonnax 10/07/13
0.5
0.5
y
0.5
0.5
0.5
0.5
0.5
0.5
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0.5
0.5
0.5
0.5
0.5
0.5
barrel
0.5
0.5
screw
screw
Visiovis design
= 0.16, = 0.52
Large change in cross channel velocity for large aspect ratio.
Back pressure effects visible at closed discharge.
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(1)
S + r S +2r d= 0
5
S=
S
+ S v S v t v S
t
(2)
<w>0
D
w = . . . + De w + De2 w
= . . . + D e
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2
1.5
1
0.5
0.4
0.3
= 1, = 0.5
0.1
0.1
0
-0.1
-0.1
-0.2
-0.2
-0.3
-0.3
-0.4
-0.4
0.3
w0 + 2 w2 with De = 0
0.5
0.4
0.3
0.2
0.2
0.1
0.1
y
-0.1
-0.1
-0.2
-0.2
-0.3
-0.3
-0.4
-0.4
-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall
-0.5
0.1 0.2 0.3 0.4 0.5
2
1.5
1
0.5
0.4
= 1, = 0.25
-0.5
0.1 0.2 0.3 0.4 0.5
2
1.5
1
0.5
0.3
0.2
w0 + w with De = 0
Torsion
0.4
0.2
0.5
2
1.5
1
0.5
-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall
w0 + 2 w2 + De w with = 0.25, De = 1
ALPlastics
oyonnax 10/07/13
0.4
0.3
0.2
0.1
0 y
-0.1
-0.5
0.1 0.2 0.3 0.4 0.5
-0.2
0
-0.3
-0.4
0.4
0.3
0.2
0.1
0 y
-0.1
-0.5
0.1 0.2 0.3 0.4 0.5
-0.2
0
-0.3
-0.4
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= 0.5, Deborah De = 1
max
0.176
0.107
0.085
0.058
2 vortices appearing,
moving towards
the side walls
with higher aspect ratio
0.5
inner wall
max
v
<w>0
V Maxwell
outer wall
aspect ratio
u
<w>0
0.5
V Maxwell
0
inner wall
outer wall
0.5
0.5
0.5
0.5
0.5
0.5
ALPlastics
oyonnax 10/07/13
w/ < w >0
2
1.5
w pflw y = 0.25
w0 + w , y = 0.25
w0 + (w + De2 wmxwl ), y = 0.25
0.5
0
0.5
0.4
0.3
0.2
0.1
0.1
0.2
0.3
x
0.4
0.5
= 0.2, De = 0.73 : shift towards the outer wall validated by F.E. Calculations
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Conclusions
2D 1/2 viscous & viscoelastic fluids flow has been solved in a screw channel
constant pitch and depth, rectangular cross-section
with torsion and curvature taken into account
New model backed precisely by 3D F.E. calculations
Pressure flow is more sensitive to helical geometry than drag flow
In pressure flow, torsion of the helical channel puts the fluid in cross channel motion
Torsion effects are important for aspect ratio larger than one
Curvature effects diminish with large aspect ratios for Newtonian fluid ...
... but remain present for viscoelastic (UCM) fluid
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Plastication:
3D nonnewtonian
transient
multiphasic
melting
isothermal
fibre
breakage
2D 1/2 helicoidal
melt
viscoelastic
buckling
criterion
nonisothermal
temperature parameter
heat transfer
Newtonian
velocity field
pathlines
nonNewtonian
screw characteristics
Visiovis
Barrel Windows
screw design
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References
[AHH+ 03] M H G Amin, A D Hanlon, L D Hall, C Marriott, S Ablett, W Wang, and W J Frith. A versatile
single-screw-extruder system designed for magnetic resonance imaging measurements.
Measurement Science and Technology, 14(10):17601768, October 2003.
[AKM95]
Cynthia K. Agemura, R. J. Kauten, and K. L. McCarthy. Flow fields in straight and tapered
screw extruders using magnetic resonance imaging. Journal of Food Engineering, 24:55
72, 1995.
[Apa05]
[BCM09]
Y. Breaux, J.-Y. Charmeau, and M. Moguedet. A simple model of throughput and pressure development for single screw. Journal of Material Technology and Processing,
209(1):611618, 2009.
[BMR+ 04] Y. Breaux, M. Moguedet, X. Raoul, JY. Charmeau, J. Balcaen, and D. Graebling. Series
solutions for viscous and viscoelastic fluids flow in the helical rectangular channel of an
extruder screw. Journal of Non-Newtonian Fluid Mechanics, 123(2-3):237257, 2004.
[CNP80]
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[FkSN82] H Fukase, T kunio, S Shinya, and K Nomura. A plasticating model for single-screw
extruders. Polymer Engineering and Science, 22(9):578586, June 1982.
[GJC00]
F Gao, Z Jin, and X Chen. A visual barrel system study of reciprocating screw injection
molding. Polymer Engineering and Science, 40(6):13341343, June 2000.
[GMS+ 89] V. B. Gupta, R. K. Mittal, P. K. Sharma, G. Menning, and J. Wolters. Some studies on
glass fiber-reinforced polypropylene. part 1: Reduction in fiber length during processing.
Polymer composites, 10(1):815, February 1989.
[Lin85]
[Mad59]
B. H. Maddock. A visual analysis of flow and mixing in extruder screws. SPE Journal,
pages 383389, May 1959.
[MGS88]
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[NOF04]
[Nun86]
[Pha13]
T.-L. Pham. Plastification des polymres fonctionnels et chargs. PhD thesis, INSA-Lyon,
2013. en cours.
[TDK67]
Z Tadmor, IJ Duvdevani, and I Klein. Melting in plasticating extruders. theory and experiments. Polymer Engineering and Science, pages 198217, July 1967.
[WLLZ99] A C-Y Wong, T Liu, J C M Lam, and F Zhu. Dynamic performance of single-screws of
different configurations. International polymer processing, 14(1):3543, 1999.
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