Extruder polymer viscosity effect

The purpose of our study was a rheological evaluation of the effect of composition on the properties of ABS resins in the molten state. Steady-state viscosity was determined over a wide range of temperatures and shear rates. The shear modulus in the molten state was determined by measurement of the diameter of the extrudate. ABS resins in the molten state behaved as an amorphous homophase polymer. The effect of the elastomer phase on the viscoelastic properties which characterize the behavior of the continuous matrix, i.e. monomer friction coefficient and molecular weight between entanglements (Me), was calculated by the application of the molecular theories. The significance of these properties in heterophase systems is discussed. 

Die swell is a complex rheological phenomenon [1], It can be observed as an extrudate with a cross-section (D which is greater than the die cross-section DJ. This effect, also known as extrudate swell, Barus effect, or % memory, is defined as the ratio D /Dq = B and is a feature of polymer melt flow. Die swell is associated with the viscoelastic nature of polymer melts as it exceeds the swelling of constant viscosity (Newtonian) fluids. Accordingly, for laminar flow situations, the swelling due to velocity profile rearrangements or mass balance considerations accounts for only 10-20% and cannot explain the 50-300% increase in extrudate cross-section of the polymer emerging out of a die. 

A method for measuring the uniaxial extensional viscosity of polymer solids and melts uses a tensile tester in a liquid oil bath to remove effects of gravity and provide temperature control cylindrical rods are used as specimens (218,219). The rod extruder may be part of the apparatus and may be combined with a device for clamping the extruded material (220). However, most of the more recent versions use prepared rods, which are placed in the apparatus and heated to soften or melt the polymer (103,111,221—223). A constant stress or a constant strain rate is applied, and the resultant extensional strain rate or stress, respectively, is measured. Similar techniques are used to study biaxial extension (101). 

This paper reviews the results of investigations into low-frequency mechanical and high-frequency (ultrasonic) vibration effects upon flowable polymeric systems, primarily, on molten commercial thermoplastics. We tried to systematize possible techniques to realize vibration in molding of polymers. Theoretical and experimental corroboration is provided for major effects obtained at cyclic (shear and bulk) strains of molten polymers and compositions based thereon. It is demonstrated that combined stress of polymeric media is attained under overlapping vibrations and this results in a decreased effective viscosity of the melts, a drop i the pressure required to extrude them through molding tools, increased critical velocities of unstable flow occurrence and a reduced load on the thrust elements of extruder screws. 

The shear viscosity can be used for relating the polymer flow properties to the processing behavior, extruder design, and many other high shear rate applications. Elongational viscosity, die swell measurements as well as residence time effects can be estimated. Typical data are shown in Figure 6. 

Determining the effect of viscous dissipation in the metering section of a single screw extruder. Consider a 60 mm diameter extruder with a4 mm channel depth and a screw speed of 60 rpm. The melt used in this extrusion system is a polycarbonate with a viscosity of 100 Pa-s, a thermal conductivity of 0.2 W/m/K and a heater temperature of 300°C. To assess the effect of viscous heating we can choose a temperature difference, AT of 30K. This simply means that the heater temperature is 30K above the melting temperature of the polymer. For this system, the Brinkman number becomes... 

Fumed silica is often used in 100 percent solids, liquid polymers. With epoxy adhesives and sealants only a few percent by weight of the additive will eliminate common problems such as slumping and separation. The fumed silica also raises the effective viscosity of the base resin to prevent other components from settling while the extrudability or spreadabil-ity is unaffected. Also note that fumed silica provides a surface that is free of texture. This is important in architectural-grade paints and sealants. 

Addition of starch has a nucleating effect, which increases the rate of crystallisation. The rheology of starch/PCL blends depends on the extent of starch granule destruction and the formation of thermoplastic starch during extrusion. Increasing the heat and shear intensities can reduce the melt viscosity, but enhance the extrudate-swell properties of the polymer. 

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