Continuous modeling and simulation of flow-swell-crystallization behaviors of viscoelastic polymer melts in the hollow profile extrusion process

The continuous viscoelastic flow, swell and crystallization behaviors of polymer melts experienced within and through out of the die/mould can significantly influence the variation of internal structure, and hence determine the performance and dimension of final products in practical processing. However, traditionally theoretical and experimental methods are difficult to be afforded to this problem. In the study, the continuous viscoelastic flow, swell and crystallization behaviors of polymer melts within and through out of practically used die/mould are investigated by means of finite element-finite difference simulation. The mathematical model of three-dimensional viscoelastic flow of polymer melts is established with Phan-Thien and Tanner constitutive model. The streamface-streamline method is introduced to adjust the swelling free surface of the extrudate. The influence of the thermal and flow state on the crystallization phenomenon are discriminated using a modified Schneider's approach. A decoupled solving algorithm for the governing equations is introduced and the corresponding penalty finite element-finite difference model is derived. The discrete elastic viscous split stress algorithm incorporating the streamline upwind scheme is adopted to improve calculation stability. The essential viscoelastic flow characteristics, extrudate swell phenomenon and flow induced crystallization of polymer melts in the hollow profile extrusion process are investigated based on the proposed mathematical model and numerical methods. Both the distribution of flow variables within the extrusion die and the variation of crystallization kinetic process within the shaped mould are successfully predicted by means of finite element-finite difference simulation of flow-swell-crystallization continuous behaviors of viscoelastic polymer melts.