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ALPlastics oyonnax 10/07/13

Plastication in injection moulding :


Principles, Numerical modeling
and in line Visualisation

Yves Breaux1,a , Jean-Yves Charmeau2,a , Thuy Linh Pham2,a


Jean Balcaen2 , Mal Moguedet3 , Richard Apaloo

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

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ALPlastics oyonnax 10/07/13

Outline
Polymer Processing : Challenges

Injection Moulding

Plastication in injection Moulding


Physics
Visualization
Modelling
Fibre breakage

Flow in screw channel

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ALPlastics oyonnax 10/07/13

Thermo-Plastics Processing : Challenges

Heat transfer Mechanics Physics, Heat transfer

melting solidification aspect


solide liquid solid geometry
pellets, powder molten polymer part
mechanical properties

plastication flow and shaping moulding


temperature, rpm pressure, flow rate, viscosity Tcryst., Tmould
shear rate, Tfusion

Processing bears an impact on thermo-mechanical history from material to part

Processing parameters 6= Physics variables

Analysis on the product (consequences) Physics causes

Instrumented machine 6= Scientific instrument

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ALPlastics oyonnax 10/07/13

Injection-Moulding
Cyclic Process : widely used for making thin parts (not hollow)

2 metering 3 injection

1 plastication

4 packing 6 cooling

5 holding 7 part ejection

Research groups main interests :


Plastication & Flow in screw barrel system
Surface defects of injection-molded parts not today

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ALPlastics oyonnax 10/07/13

Visualisation
Looking for a visualization device :

Scale relevant to polymer processing machines

Applicable to screw barrel units

continuous in line flow visualisation : 3D, no blind spots

Automated particle tracking ( particle : pellet, fibre, fluorescent tracer )

Post-treatment of position : Velocities

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].

Magnetic Resonance Imaging (MRI) on a non-metallic barrel and screw unit :


Amin (2003) [AHH+ 03], Agemura (1995) [AKM95].

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ALPlastics oyonnax 10/07/13

Visiovis Data acquisition


firewire

camera V1
mobile rack
computer H led
calibrator
usb
camera H2
clock
camera H1
particle

firewire
barrel
usb led

computer V
camera V2

Barrel : PMMA Fluorescent Particle (0.4 mm)


Screw D400.4 mmlength 6D continuously monitored by 2 over 4 cameras
Silicone oil 100Pas recording two sets of 2D pathlines

[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

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ALPlastics oyonnax 10/07/13
Visiovis : Pathlines reconstruction
Data sets of 2D positions are : filtered from noise, corrected from refraction combined to give a 3D pathline

Particle moving down and up the channel : slow near the barrel fast near the screw root

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ALPlastics oyonnax 10/07/13

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ALPlastics oyonnax 10/07/13

Visual Barrel design

Standard size barrel with :


3 optical glass windows
3 plane surfaces for visualization
and lightening (laser sheet option)
3 cameras monitoring :
plastication , flow charge dispersion

[Pha13]T.-L. Pham. Plastification des polymres fonctionnels et chargs. PhD thesis, INSA-Lyon, 2013. en cours

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ALPlastics oyonnax 10/07/13

Transparent Barrel Plastication


flow channel

flight solid bed melt pool

Solid bed width increases with screw frequency Lateral film increases when screw is idle

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ALPlastics oyonnax 10/07/13

Plastication
hopper

pellets
solid bed barrel

screw
rpm
nozzle

melt film melt pool

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]?

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ALPlastics oyonnax 10/07/13

Plastication in extrusion: Tadmors model

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

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ALPlastics oyonnax 10/07/13

Plastication : Results
Solid fraction X/W along the screw length :
1 1
Solid bed Width / Channel Width

Feed Transition Metering


0.9 0.9 Feed Transition Metering

Solid bed Width / Channel Width


0.8 0.8

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)

decreases with higher screw rpm

higher barrel temperature conflicting : increases conduction but decreases viscosity

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ALPlastics oyonnax 10/07/13

Plastication in Injection Moulding


Specifics : At the beginning of rotation the solid bed reorgan-
ises
not continuous (steady state) but cyclic
1
1

sequence of steps : rotation (extrusion-like), dwell 0,9


0,9
Injection
0,8
0,8
Extrusion
and forward injection 0,7
0,7
0,6
0,6
melting depending on the time when pellets enter 0,5
0,5
feed zone 0,4
0,4
0,3
0,3
Modelling Nunns approach [Nun86] 0,2
0,2
0,1
0,1
screw forward motion: additional melting (no solid 0
0
1 5 10 15 20
bed motion) 0 5 10 15 20

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

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ALPlastics oyonnax 10/07/13

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

Mittals [MGS88] model extended to power-law fluid :


Z l
128 3n KVrn An1 (1 exp(Ax))x
applied = dx
d3 (exp(A) 1)n 0 log( 7.4
Re
)

depends on film thickness , shear rate, viscosity K, fibre diameter d and orientation l

Fibre breaks when applied > max

New layer of fibres uncovered as the solid bed is melting

Fibre length distribution obtained starting from a uniform distribution with random orientation

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ALPlastics oyonnax 10/07/13
Fibre breakage in extrusion
Screw extraction and fibre length measurement Gupta [GMS+ 89]
Comparison between measured and calculated mass (Lw) and number(Ln) averaged fibre length
ni L2i
P P
ni L i
Ln = Pi Lw = P i

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)

PP LGF 9mm on a 38mm diameter screw


agreement is good at low rpm, less so at higher rpm
[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
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ALPlastics oyonnax 10/07/13
Dcembre 2005

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ALPlastics oyonnax 10/07/13

Flow in a screw channel


Flow provoked by screw rotation and back pressure of the die downstream

y D Vx

x N Vz
z V y

L x H

z
W

Parallel Plates Model :

Rotating barrel around a static screw : steady-state problem

Unwound Channel: H  RB : no direct effects of torsion and curvature

High aspect ratio: H  W : no direct effects of screw flights

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ALPlastics oyonnax 10/07/13

Single screw throughput calculations

Pressure BackPressure
BackPressure = Palim + Pcomp + Pmeter


Screw Diameter

Hfeed m = m Qliq + s Vsz HX


Q? W X
W
rpm = HX
m Q
Hmeter 1 Halim Walim

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:

screw forward displacement (drag flow), Vbz W H


Q = |6G|s sgn(G)f ()
(1 + s)(1 + 2s)
pressure gradient in the screw channel.
H n+1 (z) dP
Pressure development begins at atmospheric G =
6KV0n dz
pressure and ends at Back pressure imposed
on the screw

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ALPlastics oyonnax 10/07/13
Throughput and Pressure profiles
100 30 40

pressure (MPa)
pressure (MPa)
modele Debit (kg/h)

exp. Md=32.2 kg/h exp. Md=99.6 kg/h


PS Styron, T 211C
90 35
PC Lexan, T 285C 25
80 30
20
70 25

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

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ALPlastics oyonnax 10/07/13

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

No leakage flow through barrel/screw clearance

Perturbation method
pressure & drag flow of viscous fluids
pressure flow of viscoelastic fluids

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ALPlastics oyonnax 10/07/13
Rectangular helical screw channel
z
r

y x 2P

B W/2
R H/2
N
T

Geometry Dimensionless Numbers


Hydraulic Diameter D = 2HW = W
H +W H
Curvature = R  = D
R + P2
2

Torsion = P = D
R + P2
2

Helix Angle tan() = P tan() =


R 

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ALPlastics oyonnax 10/07/13

Applicability

Visiovis Extruder (pumping zone)


Aspect ratio 6.9 21.8
Curvature  0.44 0.15
Torsion 0.16 0.05
tan() 0.36 0.33


Curvature  and torsion are small but not negligible dimensionless parameters

Aspect ratios are very large

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ALPlastics oyonnax 10/07/13

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

Tore () Helix (, ) Straight twisted duct ()

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ALPlastics oyonnax 10/07/13
Pressure flow/Newtonian fluid
w0 w0 + 2 w2 w0 + w + 2 w2
=1 0.5 0.5 0.5

0.4 0.4 0.4

0.3 0.3 0.3

0.2 0.2 0.2

0.1 0.1 0.1

0 y 0 y 0 y

-0.1 -0.1 -0.1

-0.2 -0.2 -0.2

-0.3 -0.3 -0.3

-0.4 -0.4 -0.4

-0.5 -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 -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 outer wall <--- x --> inner wall

= 1/5 0.5 0.5 0.5

0.4 0.4 0.4

0.3 0.3 0.3

0.2 0.2 0.2

0.1 0.1 0.1

0 y 0 y 0 y

-0.1 -0.1 -0.1

-0.2 -0.2 -0.2

-0.3 -0.3 -0.3

-0.4 -0.4 -0.4

-0.5 -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 -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 outer wall <--- x --> inner wall

Curvature : max velocity shifting towards the inner wall


Torsion : max velocity decreases

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ALPlastics oyonnax 10/07/13

Pressure flow, curvature effects


2.5

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)

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ALPlastics oyonnax 10/07/13

Pressure flow, torsion effects


Down-channel velocity w Cross-channel velocity u, v,
2 0.25

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

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oyonnax 10/07/13

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

w0d + wd + 2 /w2 / GP (w0 + w + 2 w2 + 2 w2 )


0.2 0.2
0.1 0.1

 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

Drag & pressure flow, cross-channel velocity V , = 1


V0 V
0.5 0.5

0 0

y
y
0.5 0.5
0.5 0 x 0.5 0.5 0 x 0.5

Cavity-lid driven flow (unwound channel) perturbation solution (helical geometry)

At closed discharge with = 1, = 0.25,  = 0.5

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ALPlastics oyonnax 10/07/13

Drag & pressure flow, cross-channel velocity V , = 7

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.

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ALPlastics oyonnax 10/07/13

Viscoelastic fluid flow


Differential viscoelastic model : Upper-Convected Maxwell
5 5
S + r S +2r d= 0 (1)

5 S
S= + S v S v t v S (2)
t
First normal stress difference & constant shear viscosity

Developed in Frenet basis ( 1000 terms)

Zero order analytic solution available in pressure flow only

Expansion of each stress component in power of , 

At a given order, stress components are now explicit functions of known velocity gradients

Creates specific contribution to the flow :


<w>0
Deborah number: De = D

w = . . . + De w + De2 w
= . . . + D e 

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ALPlastics oyonnax 10/07/13
Viscoelastic fluid, pressure flow, w
Curvature pressure flow - Wp Newton - aspect 1 pressure flow - Wp Maxwell - aspect 1
2 0.5 2 0.5
1.5 1.5
1 0.4 1 0.4
0.5 0.5
0.3 0.3

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

= 1,  = 0.5 w0 + w with De = 0 w0 + w + De2 wmxwl with  = 0.5, De = 1


Torsion pressure flow - Wp Newton - aspect 1 pressure flow - Wp Maxwell - aspect 1
2 0.5 2 0.5
1.5 1.5
1 0.4 1 0.4
0.5 0.5
0.3 0.3

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

= 1, = 0.25 w0 + 2 w2 with De = 0 w0 + 2 w2 + De w with = 0.25, De = 1


ALPlastics oyonnax 10/07/13
Viscoelastic fluid, pressure flow, w

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

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ALPlastics oyonnax 10/07/13
Viscoelastic fluid, pressure flow, cross-channel velocity u, v

 = 0.5, Deborah De = 1 V  Maxwell


2 vortices appearing, 0.5
aspect ratio max u
max v y
<w>0 <w>0
moving towards
1 0.176 0.107
the side walls
5 0.085 0.058

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

0.5 w pflw y = 0.25


w0 + w , y = 0.25
w0 + (w + De2 wmxwl ), y = 0.25 x
0
0.5 0.4 0.3 0.2 0.1 0 0.1 0.2 0.3 0.4 0.5

 = 0.2, De = 0.73 : shift towards the outer wall validated by F.E. Calculations

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ALPlastics oyonnax 10/07/13

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

Strong corrections to the PPM model are needed in view of finer


calculations of mixing efficiency and overall residence time
and screw design
[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

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ALPlastics oyonnax 10/07/13

Plastication: synthesis and perspectives


3D nonnewtonian transient nonisothermal multiphasic melting

stationnary (static vis, rotating barrel)

isothermal temperature parameter nonisothermal heat transfer

fibre 2D 1/2 helicoidal 1D Flow Analysis Network 1D plastication extrusion and injection
breakage Newtonian
melt viscoelastic nonNewtonian
fibre breakage (solid/melt)

distribution longueur fibres


buckling velocity field screw characteristics plastication profile
criterion pathlines

Visiovis Barrel Windows

screw design

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