Cover image for Polymer melt fracture
Title:
Polymer melt fracture
Personal Author:
Publication Information:
Boca Raton, FL : Taylor & Francis, 2010.
Physical Description:
ix, 319 p. : ill ; 24 cm.
ISBN:
9781574447804
General Note:
"A CRC title."

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30000010257264 TA455.P58 K65 2010 Open Access Book Book
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Summary

Summary

The continually growing plastics market consists of more than 250 million tons of product annually, making the recurring problem of polymer melt fracture an acute issue in the extrusion of these materials. Presenting a pictorial library of the different forms of melt fracture and real industrial extrusion melt fracture phenomena, Polymer Melt Fracture provides pragmatic identification and industrial extrusion defect remediation strategies based on detailed experimental and theoretical findings from the last 50 years.

Distinct microscopic photos

Each chapter in this comprehensive volume covers a different aspect of the science and technology relating to polymer melt fracture. The book begins with a collection of optical and scanning electron microscopy pictures. These photos show distorted capillary die extrudates for a number of commercially available polymers. The authors present a brief introduction to the basic science and technology of polymers. They explain what polymers are, how they are made, and how they can be characterized. They also discuss polymer rheology, review the principles of continuum mechanics, and define linear viscoelastic material functions.

Techniques for observing and measuring fracture

Next, the book explains how polymer melt fracture is actually experienced in the polymer processing industry. It explains the various ways polymer melt fracture may appear during polymer melt processing in different extrusion processes. The authors provide comprehensive reviews of the polymer melt fracture literature, with chapters on experimental findings and the techniques used to observe and measure polymer melt fracture, and the influence of polymer architecture and polymer processing conditions on the onset and types of polymer melt fracture. Posing a hypothesis about the phenomenon, the book presents the current understanding of polymer melt fracture.

Mathematical equations

Recognizing the importance of models for simulations that may indicate potential solutions, the book discusses aspects of non-linear constitutive equations and microscopic theory and develops a macroscopic model, explaining the capabilities and limitations of this approach. The book presents an overview of pragmatic tools and methods that have been used to prevent the appearance of polymer melt fracture and explains how to use them to suppress defects.


Author Notes

Rudy Koopmans received his PhD in physical and macromolecular chemistry from the University of Antwerp in Belgium. He is a fellow in the Basic Plastics R&D organization of The Dow Chemical Company located in Horgen, Switzerland. Since joining Dow in 1983, he has held various R&D positions in Europe and the United States. His main R&D focus is on materials development, polymer processing, and developing innovative technology solutions to market needs and identified market trends. In addition, he holds a visiting professorship at Leeds University in the United Kingdom in the Department of Chemical Engineering. He has published more than 50 peer-reviewed papers in international journals and books, and is a holder of multiple patents.

Jaap den Doelder received his MSc in applied physics and applied mathematics at Eindhoven University of Technology in the Netherlands. He received his PhD in applied mathematics at the same university in 1999 on the topic of polymer melt fracture. The same year, he joined The Dow Chemical Company in Terneuzen, the Netherlands. He has since worked on a variety of topics related to materials science and modeling of polymers, connecting application requirements to molecular design. He is currently a research scientist in Dow's polyethylene business.

Jaap Molenaar studied mathematics and theoretical physics at Leiden University in the Netherlands and wrote a PhD thesis on the field of solid state physics. For more than a decade he was involved in mathematics consulting. He received the Neways Award for his work on academic knowledge transfer to industry. He specializes in the modeling of dynamical systems in terms of differential equations and has published several books on these topics. His research focuses on fluid mechanics, in particular polymer melt flow. Recently, he became active in systems biology. He is a full professor in applied mathematics and the head of department for Mathematical and Statistical Methods for the Life Sciences of Wageningen

University and Research Centre in the Netherlands.


Table of Contents

Forewordp. xv
Prefacep. xvii
Authorsp. xxi
Chapter 1 Polymer Melt Fracture Picturesp. 1
1.1 Optical Microscopyp. 2
1.2 Scanning Electron Microscopyp. 10
Referencep. 20
Chapter 2 Polymer Characteristicsp. 21
2.1 Polymersp. 22
2.1.1 Polymer Architecturep. 24
2.1.2 Molar Mass Distributionp. 28
2.1.3 Polymerization Processesp. 32
2.2 Polymer Characterizationp. 35
2.2.1 Polymer Architecturep. 35
2.2.1.1 Spectrometry: Ultraviolet, Visible, Infrared, and Ramanp. 36
2.2.1.2 Nuclear Magnetic Resonance Spectrometryp. 36
2.2.1.3 Densityp. 39
2.2.1.4 Thermal Analysisp. 39
2.2.2 Molar Mass, Molar Mass Distributionp. 40
2.2.2.1 Dilute Solution Viscosityp. 41
2.2.2.2 Light Scatteringp. 43
2.2.2.3 Colligative Property Measurement Techniquesp. 44
2.2.2.4 Gel Permeation Chromatographyp. 45
2.2.2.5 Fractionationp. 46
2.2.2.6 Rheologyp. 47
2.3 General Observationp. 49
Referencesp. 50
Chapter 3 Polymer Rheologyp. 53
3.1 Continuum Mechanicsp. 53
3.2 Scalars, Vectors, and Tensorsp. 54
3.3 Stress Tensorp. 58
3.4 Strain Tensorsp. 59
3.4.1 Finger Tensorp. 59
3.4.2 Rate of Deformation and Vorticity Tensorp. 63
3.4.3 Relation between Finger Tensor B and Rate of Deformation Tensor Dp. 65
3.5 Equations of Motionp. 65
3.5.1 Transport Theoremp. 66
3.5.2 Mass Balancep. 67
3.5.3 Momentum Balancep. 68
3.6 Constitutive Equationsp. 71
3.6.1 Elastic Behaviorp. 71
3.6.2 Viscous Behaviorp. 72
3.6.3 Viscoelastic Behaviorp. 75
3.6.4 Linear Viscoelasticityp. 78
3.6.5 Compliance Functionp. 80
3.7 General Observationp. 84
Referencesp. 84
Chapter 4 Polymer Processingp. 87
4.1 Extrusionp. 87
4.1.1 Granulationp. 88
4.1.2 Film Blowingp. 88
4.1.3 Film and Sheet Castingp. 93
4.1.4 Extrusion Blow Moldingp. 95
4.1.5 Wire Coatingp. 97
4.1.6 Pipe and Profilep. 98
4.1.7 Fiber Spinningp. 98
4.1.8 Co-Extrusionp. 101
4.2 Injection Moldingp. 102
4.3 Rotational Moldingp. 103
4.4 Calenderingp. 103
4.5 General Observationp. 104
Referencesp. 105
Chapter 5 Melt Fracture Experimentsp. 109
5.1 Constant-Pressure and Constant-Rate Experimentsp. 110
5.1.1 Discontinuous Flow Curvesp. 114
5.1.2 Continuous Flow Curvesp. 120
5.2 Flow Visualizationp. 122
5.2.1 Particle Trackingp. 124
5.2.2 Flow Birefringencep. 126
5.2.3 Stacked Colorsp. 130
5.3 Critical Numbersp. 131
5.3.1 Reynolds Numberp. 132
5.3.2 Weissenberg and Deborah Numberp. 132
5.3.3 Recoverable Strainp. 134
5.3.4 Critical Stressp. 135
5.4 Melt Fracture Observationp. 139
5.4.1 Microscopyp. 139
5.4.2 Profilometryp. 140
5.4.3 Indirect Methodsp. 141
5.4.4 Melt Fracture Quantificationp. 144
5.5 Change of Slopep. 147
5.6 Wall Slipp. 148
5.6.1 The Mooney Methodp. 148
5.6.2 The Laun Methodp. 151
5.6.3 Other Methodsp. 153
5.7 Compressibilityp. 154
5.8 General Observationp. 155
Referencesp. 156
Chapter 6 Melt Fracture Variablesp. 167
6.1 Polymer Architecturep. 167
6.2 Polymer-Processing Variablesp. 174
6.2.1 Length-Radius Ratiop. 174
6.2.2 Die Entry and Exit Anglep. 179
6.2.3 Die Construction Materialp. 182
6.2.4 Die Surface Roughnessp. 184
6.2.5 Die Surface Modifierp. 186
6.2.6 Temperaturep. 187
6.3 General Observationp. 192
Referencesp. 193
Chapter 7 Understanding Melt Fracturep. 201
7.1 Melt Fracture Mechanismsp. 202
7.1.1 Reynolds Turbulencep. 202
7.1.2 Thermal Catastrophep. 202
7.1.3 Stress-Induced Fractionationp. 202
7.1.4 Fracturep. 202
7.1.5 Cavitationp. 205
7.1.6 Interfacial Slipp. 205
7.1.6.1 Microscopic Mechanisms-Cohesive Failurep. 207
7.1.6.2 Microscopic Mechanisms-Adhesive Failurep. 209
7.2 The Constitutive Approachp. 211
7.2.1 Phenomenologyp. 211
7.2.2 Relaxation Oscillationsp. 212
7.2.3 Numerical Simulationsp. 214
7.2.4 Molecular Considerationsp. 215
7.3 General Understandingp. 218
7.4 General Observationp. 225
Referencesp. 226
Chapter 8 Advanced Polymer Rheologyp. 233
8.1 Molar Mass, Zero-Shear Viscosity, and Recoverable Compliancep. 234
5.2 Continuous Models and Frame Invariancep. 237
8.2.1 Upper-Convected Maxwell Modelp. 239
8.2.2 Johnson-Segalman-(Oldroyd) Modelsp. 241
8.2.2.1 Johnson-Segalman Modelp. 241
8.2.2.2 Johnson-Segalman-Oldroyd Modelp. 244
8.2.3 Kaye-Bernstein-Kearsley-Zapas Modelp. 245
8.3 Microscopic Modelsp. 248
8.3.1 Rouse Modelp. 250
8.3.2 Reptation Modelp. 253
8.3.3 Branchingp. 258
8.3.4 Pom-Pom Modelp. 259
8.4 Molar Mass Distribution and Linear Viscoelasticityp. 261
8.5 General Observationp. 263
Referencesp. 263
Chapter 9 Modeling Melt Fracturep. 267
9.1 The Relaxation-Oscillation Modelp. 268
9.2 Coupling RO and Constitutive Equationsp. 271
9.3 Slip-Boundary Conditionsp. 275
9.4 A Rheological Model Including Wall Slipp. 280
9.5 Bulk and Interfacial Viscosity Balance for Different Polymersp. 284
9.6 Flow Curve and Melt Fracture Relationp. 287
9.6.1 "Spurt" Distortionsp. 288
9.6.2 Surface Distortionsp. 288
9.6.3 Volume Distortionsp. 290
9.7 General Observationp. 290
Referencesp. 291
Chapter 10 Preventing Melt Fracturep. 295
10.1 Additivesp. 295
10.1.1 Slip Agentsp. 297
10.1.2 Polymer Blendsp. 298
10.1.3 Waxp. 299
10.1.4 Fillersp. 299
10.2 Extruder and Processing Conditionsp. 300
10.3 Dealing with Melt Fracturep. 303
10.3.1 Melt Fracture Checklistp. 305
10.4 General Observationp. 305
Referencesp. 306
Indexp. 313