Thermally-induced extrudate swell

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Abstract
In many polymer processing applications, the generation of heat by viscous losses in the flowing molten polymer is highly significant. The heating reduces the viscosity of the melt sharply and the flow patterns are different from the isothermal case. In this paper, a finite element scheme based on the Galerkin method is developed and is used to explore the effects of thermally induced property changes in extrusion. In the program we solve simultaneously for the flow and temperature fields at each iteration. To check the program for accuracy and correctness, some simple problems were first attempted. A solution for viscous heating in Poiseuille flow was used to check the variable-viscosity part of the program. The crucial convection (‘radiation’) boundary condition was checked using the solution for cooling of a moving rod. Finally, the swelling of extruded jets with self-heating was investigated. A new phenomenon, thermal extrudate swell, was thereby discovered. We have found extrudate expansions up to 70% of the die diameter in a Newtonian fluid with thermal properties similar to those of low density polyethylene. It is clear that this phenomenon will affect many experimental interpretations of extrudate swelling.

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