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Polymer Processing and Rheology

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Functional Polymers

Part of the book series: Polymers and Polymeric Composites: A Reference Series ((POPOC))

Abstract

This chapter is devoted to the presentation of the fundamental rheological properties of polymers and their processing technologies. Measurements of the rheological properties offer a fast and reliable way to determine molecular weight distribution and long-chain branching, which, in combination with the processing conditions, have a decisive influence on the end-use product properties. Shear viscosity, elongational viscosity, normal stress differences, stress relaxation, and some other measures and rheological phenomena, of relevance to polymer processing, are discussed. The most widely used polymer processing technologies of extrusion and injection molding are discussed with some details. The discussion includes key features of equipment used and design and operation challenges. Brief descriptions are presented on calendering, compression molding, blow molding, thermoforming, rotational molding, fiber spinning, and additive manufacturing. It is argued that computer-aided flow analysis and rheological measurements are necessary for equipment design, troubleshooting, and optimization in the processing of thermoplastics.

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Abbreviations

ABS:

Acrylonitrile butadiene styrene

AM:

Additive manufacturing

CaBER:

Capillary breakup extensional rheometer

EVA:

Ethylene-vinyl acetate

FDM:

Fused deposition modeling

HDPE:

High-density polyethylene

HLMI:

High load melt index

LAOS:

Large amplitude oscillatory shear

LDPE:

Low-density polyethylene

LLDPE:

Linear low-density polyethylene

LVE:

Linear viscoelasticity

MFI:

Melt flow index

MFR:

Melt flow rate

MI:

Melt index

MWD:

Molecular weight distribution

OEMs:

Original equipment manufacturers

PA:

Polyamide

PC:

Polycarbonate

PE:

Polyethylene

PET:

Polyethylene terephthalate

PP:

Polypropylene

PLA:

Polylactic acid

PMMA:

Polymethyl methacrylate

PS:

Polystyrene

PVC:

Polyvinyl chloride

RIM:

Reaction injection molding

RPM:

Revolutions per minute

SAOS:

Small amplitude oscillatory shear

SER:

Sentmanat extensional rheometer

SLS:

Selective laser sintering

SMEs:

Small and medium enterprises

SSE:

Single screw extruder

TSE:

Twin screw extruder

WFC:

Wood fiber composite

α :

Fitting parameter in Carreau-Yasuda model

γ :

Strain

\( \dot{\gamma} \) :

Shear rate

\( {\dot{\gamma}}_{\mathrm{app}} \) :

Shear rate (apparent)

\( {\dot{\gamma}}_{\mathrm{true}} \) :

Shear rate (true)

\( {\dot{\gamma}}_w \) :

Wall shear rate

ΔP:

Pressure drop

ΔPe:

Excess pressure drop

\( \dot{\varepsilon} \) :

Elongation rate

η :

Viscosity

η c :

Viscosity of the filled system

η d :

Viscosity of the dispersed phase

η e :

Elongational viscosity

η m :

Viscosity of the matrix

η o :

Zero shear viscosity

η * :

Complex viscosity

η ref :

Viscosity at a reference temperature

θ :

Screw helix angle

λ :

Fitting parameter in Carreau-Yasuda, cross models

ρ :

Melt density

σ 11 :

Tensile stress

τ :

Shear stress

τ w :

Wall shear stress

φ :

Volume fraction

φ max :

Maximum volume fraction

ω :

Frequency

A :

Area

A c :

Cross section of a cylindrical fluid element

a :

Pressure coefficient

b :

Temperature sensitivity coefficient

Ca :

Capillary number

d :

Extrudate diameter

D :

Capillary diameter

D b :

Barrel diameter

E :

Activation energy

F :

Force

G′ :

Storage modulus

G″ :

Loss modulus

h :

Gap between plates

H :

Channel depth in an extruder

H o :

Minimum distance between two rollers

k :

Einstein coefficient frequently denoted as [η]

K :

Consistency index

L :

Capillary length

M w :

Weight average molecular weight

N :

Rotational speed

N 1 :

First normal stress difference

N 1w :

First normal stress difference at the wall

N 2 :

Second normal stress difference

n :

Power law index

n B :

Bagley correction

p :

Pressure

P max :

Maximum pressure in calendering

Q :

Volume rate of flow

R :

Gas constant

R c :

Capillary radius

R d :

Drop radius

R rol :

Roller radius

S :

Interfacial tension

S R :

Stress ratio

t :

Time

T :

Temperature

T ref :

Reference temperature

U :

Velocity/speed

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Author information

Authors and Affiliations

  1. Polydynamics Inc., Dundas, ON, Canada

    Nickolas D. Polychronopoulos

  2. Department of Chemical Engineering, McMaster University, Hamilton, ON, Canada

    John Vlachopoulos

Authors
  1. Nickolas D. Polychronopoulos
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  2. John Vlachopoulos
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Correspondence to John Vlachopoulos .

Editor information

Editors and Affiliations

  1. Minerals, King Fahd University of Petroleum a, Dhahran, Saudi Arabia

    Mohammad Abu Jafar Mazumder

  2. McMaster University, Hamilton, ON, Canada

    Heather Sheardown

  3. Minerals, King Fahd University of Petroleum a, Dhahran, Saudi Arabia

    Amir Al-Ahmed

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Polychronopoulos, N.D., Vlachopoulos, J. (2019). Polymer Processing and Rheology. In: Jafar Mazumder, M., Sheardown, H., Al-Ahmed, A. (eds) Functional Polymers. Polymers and Polymeric Composites: A Reference Series. Springer, Cham. https://doi.org/10.1007/978-3-319-92067-2_4-1

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  • DOI: https://doi.org/10.1007/978-3-319-92067-2_4-1

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