Académique Documents
Professionnel Documents
Culture Documents
1
LaMCoS UMR5259, INSA-Lyon
2
IMP@INSA UMR5223, INSA-Lyon
3
PEP,Centre Technique de la Plasturgie
a
Filire Gnie Mcanique Procds Plasturgie, INSA-Lyon
Outline
Polymer Processing : Challenges
Injection Moulding
Injection-Moulding
Cyclic Process : widely used for making thin parts (not hollow)
2 metering 3 injection
1 plastication
4 packing 6 cooling
Visualisation
Looking for a visualization device :
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].
camera V1
mobile rack
computer H led
calibrator
usb
camera H2
clock
camera H1
particle
firewire
barrel
usb led
computer V
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
Particle moving down and up the channel : slow near the barrel fast near the screw root
[Pha13]T.-L. Pham. Plastification des polymres fonctionnels et chargs. PhD thesis, INSA-Lyon, 2013. en cours
Solid bed width increases with screw frequency Lateral film increases when screw is idle
Plastication
hopper
pellets
solid bed barrel
screw
rpm
nozzle
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]?
v
fourreau Tb
u Vbx U2 m km (Tb Tm ) (1 + Br U1 ) X
u
Vbx =
mlt t
Ethlpy
1111111111
0000000000
0000000000
1111111111
Vsy
0000000000
1111111111
0000000000
1111111111 dimensionless numbers : Br self heating (vis-
0000000000
1111111111
Tm
0000000000
1111111111
X
0000000000
1111111111 cous dissipation), A Thermo-dependence
0000000000vis
1111111111
KVrn+1 1n
W Br =
km (Tb Tm )
Fusion : contact and melt renewal a(T b Tm )
A =
n
Thermo-dependent power-law viscosity =
K exp(a(T Tm )) n1 Melt film thickness :
Solid bed : width X, velocity Vsz . Channel H,
mlt
W . Mass flow rate mlt : =
m Vbx U2 (A)
= d
mlt (s HXVsz )
dz
Plastication : Results
Solid fraction X/W along the screw length :
1 1
Solid bed Width / Channel Width
0.7 0.7
0.6 0.6
0.5 0.5
Pryltex
0.4 0.4 screw 90mm
PP
0.3 0.3 Pryltex rpm 40 Tb 240C
HDPE
rpm +50%
0.2 0.2
rpm 40
rpm +50% BP +50%
0.1 screw 90mm 0.1
Tb +50C
0 0
2 4 6 8 10 12 14 16 18 2 4 6 8 10 12 14 16 18
N screw/turn N screw/turn
Plastication length :
increases with shear rate (increase viscous dissipation) (at a given throughput)
2
!
km (Tb Tm ) + Sinj
X = X0 exp tinj melting length shorter
Hm Ethlpy
residence time is much longer
dwell : film thickness increases by transient con- [Apa05] R. E. Apaloo. Plastification en injection. simplast.
duction Masters thesis, Insa-Lyon, GMPP, 2005
s
km (Tb Tm )tdwell
= + 0
s
Fibre Breakage
Fibres anchored at one end in solid bed, submitted at the other end to intense shear
Vbx fourreau
111111
000000
0
1
111111
000000
0
1
000000
111111
0
1 l 000000000
111111111
d
000000000
111111111
000000
111111
0
1
00000000000000
11111111111111
000000000
111111111
000000
111111
00000000000000
11111111111111
000000
111111
00000000000000
11111111111111
00000000000000
11111111111111
00000000000000
11111111111111
lit solide
00000000000000vis
11111111111111
depends on film thickness , shear rate, viscosity K, fibre diameter d and orientation l
Fibre length distribution obtained starting from a uniform distribution with random orientation
i ni i ni Li
10 40 80
Ln exp Lw exp = 3.85 mm
Ln calc
Lw exp 35 Lw calc = 3.60 mm 70
Lw calc Ln exp = 1.05 mm
8
fraction en nombre %
Ln calc = 1.10 mm
fraction en masse %
30 60
25
Ln,Lw (mm)
50
6
20 40
4 15 30
10 20
2
5 10
0 0 0
0 5 10 15 20 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
N D_Vis longueur fibre (mm) longueur fibre (mm)
y D Vx
x N Vz
z V y
L x H
z
W
Pressure BackPressure
BackPressure = Palim + Pcomp + Pmeter
Screw Diameter
Lfeed Lcomp Lmeter 1D relationship between flow rate and local pres-
3 zone screw viewed as a melt pump where : sure gradient for power-law fluids:
pressure (MPa)
pressure (MPa)
modele Debit (kg/h)
60 15 20
50 15
10
40 rpm=40 rpm=100
10% 10
model Md=35.9 kg/h model Md=103.4 kg/h
30 5
5
model + plast. Md=35.5 kg/h model + plast. Md=90.8 kg/h.
20 essai Debit (kg/h) 0 0
0 5 10 15 20 25 30 0 5 10 15 20 25 30
20 30 40 50 60 70 80 90 100 N screw turn 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
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
Perturbation method
pressure & drag flow of viscous fluids
pressure flow of viscoelastic fluids
y x 2P
B W/2
R H/2
N
T
Torsion = P = D
R + P2
2
Applicability
Curvature and torsion are small but not negligible dimensionless parameters
Overview
Fluid Flow type Flow direction Helicity
viscous drag down-channel w curvature
viscoelastic pressure cross-channel u, v, torsion
Ducts
y
X Z
y
Z
Y
Z
X
0 y 0 y 0 y
0 y 0 y 0 y
w/w0av
2
1.5
w plfw, y = 0
1
w plfw, x = 0
w0 + w + 2 w2 , y = 0
0.5 w0 + w + 2 w2 , x = 0
w0 + w , y = 0
x, y
0
0.5 0.4 0.3 0.2 0.1 0 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)
1.8
x
0.2
1.6 0.15
y
1.4 Z
0.1 u plfw, y = 0.25
y
1.2 u , y = 0.25
w/w0av
u/w0av
0.05
1
u plfw, x = 0
0
w0 + 2 w2 , y = 0 u , x = 0
0.8 0.05 u plfw, x = 0.25
w0 + 2 w2 , x = 0 u , x = 0.25
0.6 w0 , y = 0 0.1
x w0 , x = 0
0.4 0.15
w plfw, y = 0
0.2 y w plfw, x = 0 0.2
0 0.25
0.5 0.4 0.3 0.2 0.1 0 0.1 0.2 0.3 0.4 0.5 0.5 0.4 0.3 0.2 0.1 0 0.1 0.2 0.3 0.4 0.5
x, y x, y
= 2, = 0.6, = 0 = 5, = 0.15, = 0
Narrower w profile Secondary flow created
u scales like 1+
4
w0av when > 1
FULL SCREEN
drag pressure flow - W0dp - aspect 5 drag pressure flow - Wdp - aspect 5
0.5 0.5
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 0.0
-0.1 0.4 -0.1 0.4
-0.2 -0.2
-0.3 -0.3
Drag & pressure flow, down-channel velocity w
0.3 0.3
Visiovis design = 7 = 0.16 = 0.52, at closed discharge
page 28
w0d GP w0
0 y 0 y
-0.1 -0.1
-0.2 -0.2
-0.3 -0.3
-0.4 -0.4
ALPlastics
-0.5 -0.5
-0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5
BACK
outer wall <--- x --> inner wall outer wall <--- x --> inner wall
ALPlastics oyonnax 10/07/13
0 0
y
y
0.5 0.5
0.5 0 x 0.5 0.5 0 x 0.5
0.5
0.5
V y V y
0.5
0.5
barrel barrel
0
0
0.5
0.5
0
0
x
x
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.
5 S
S= + S v S v t v S (2)
t
First normal stress difference & constant shear viscosity
At a given order, stress components are now explicit functions of known velocity gradients
w = . . . + De w + De2 w
= . . . + D e
0.2 0.2
0.1 0.1
0 y 0 y
-0.1 -0.1
-0.2 -0.2
-0.3 -0.3
-0.4 -0.4
-0.5 -0.5
-0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5
outer wall <--- x --> inner wall outer wall <--- x --> inner wall
0.2 0.2
0.1 0.1
0 y 0 y
-0.1 -0.1
-0.2 -0.2
-0.3 -0.3
-0.4 -0.4
-0.5 -0.5
-0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5
outer wall <--- x --> inner wall outer wall <--- x --> inner wall
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1
-0.5 -0.4 -0.3 -0.2 -0.1
outer wall <---
x
0
0.1 0.2 0.3 0.4 0.5
--> inner wall
-0.5
-0.4
-0.3
-0.2
-0.1
0 y
0.1
0.2
0.3
0.4
0.5
Curvature, w0 + w + De2 wmxwl with = 0.5, De = 1, = 5
Large change in contours of w near the side walls
0.2
0.4
0.6
0.8
1.2
1.4
1.6
1
-0.5 -0.4 -0.3 -0.2 -0.1
outer wall <---
x
0
0.1 0.2 0.3 0.4 0.5
--> inner wall
-0.5
-0.4
-0.3
-0.2
-0.1
0 y
0.1
0.2
0.3
0.4
0.5
Torsion, w0 + De w + 2 w2 with = 0.25, De = 2, = 5
Small twist in contours of w near the side walls
outer wall
inner wall
with higher aspect ratio
V Maxwell
0.5
0
y
outer wall
inner wall
0.5
0.5 0 x 0.5
0.5
0.5 0 x 0.5
ALPlastics oyonnax 10/07/13
Viscoelastic fluid, pressure flow, w
2.5
w/ < w >0 w0 + (w + De2 wmxwl ), y = 0
w0 + w , y = 0
2 w pflw y = 0
1.5
= 0.2, De = 0.73 : shift towards the outer wall validated by F.E. Calculations
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
fibre 2D 1/2 helicoidal 1D Flow Analysis Network 1D plastication extrusion and injection
breakage Newtonian
melt viscoelastic nonNewtonian
fibre breakage (solid/melt)
screw design
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] R. E. Apaloo. Plastification en injection. simplast. Masters thesis, Insa-Lyon, GMPP,
2005.
[BCM09] Y. Breaux, J.-Y. Charmeau, and M. Moguedet. A simple model of throughput and pres-
sure 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] K. P. Choo, N. R. Neelakantan, and J. F. T. Pittman. Experimental deep-channel velocity
[NOF04] M. Noriega, T. A. Osswald, and N. Ferrier. In line measurement of the polymer melting
behavior in single-screw extruders. SPE-ANTEC Technical papers, 50:154161, 2004.
[Nun86] R E Nunn. The reciprocating Screw Process, chapter 3, pages 5683. 1986.
[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 experi-
ments. 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.