Effect of characteristic scale on the extrudate swelling behavior of polypropylene melt in a micro‐extrusion process

Study on the Melt Rheological Characterization of Micro-Tube Gas-Assisted Extrusion Based on the Cross-Scale Viscoelastic Model

In the micro-tube gas-assisted extrusion process, flow theories ignoring cross-scale viscoelastic variations fail to effectively characterize the rheological state of the melt. To investigate the impact of cross-scale viscoelastic variation on the quality of the micro-tube gas-assisted extrusion, a 3D multiphase flow extrusion model incorporating a double gas-assisted layer was developed. Subsequently, we modified the DCPP constitutive equations based on the cross-scale factor model. Both the traditional and gas-assisted extrusions were simulated under macroscale and cross-scale models using the Ansys Polyflow. Finally, using the established gas-assisted extrusion platform, extrusion experiments were conducted. The results indicate that, owing to the reduced melt viscosity under the cross-scale model, the deformation behavior of the melt is more pronounced than in the macroscale model. The cross-scale model's numerical results more closely match the experimental outcomes under the same parameters, thereby confirming the feasibility of the theoretical analysis and numerical simulation. Moreover, the predictive capability of the cross-scale model for the micro-tube gas-assisted extrusion is further validated through numerical and experimental analyses with varying parameters. It is demonstrated that the cross-scale viscoelastic variation is a critical factor that cannot be overlooked in the gas-assisted extrusion.

Effects of gas-assisted technology on polymer micro coextrusion

In this paper, a three-dimensional viscoelastic flow model of double-layer micro coextrusion with circular cross-section was established. The simulations were carried out by the finite element method and the influence of wall slip coefficient on micro coextrusion was studied. The results show that gas-assisted technology is suitable for polymer micro coextrusion forming. The differences between the gas-assisted and conventional micro coextrusion process were compared by analyzing the distribution of melts velocity, pressure, shear rate and first normal stress difference. The research results show that in the conventional micro coextrusion process there are pressure drop, shear rate, first normal stress difference and secondary flow. And there is a gradient distribution of melts velocity. The die swell and deformation vary with the forming process parameters, and it is difficult to control the product quality. But in the gas-assisted micro coextrusion process, there is no pressure drop, shear rate, first normal stress difference and secondary flow. The velocity of polymer melts is evenly distributed and the melts are extruded in a plunger shape. The melts do not swell and deform and it is independent of forming process parameters. It is easy to ensure the products quality and the inherent problems of polymer conventional micro coextrusion are well solved.

A Combined Experimental and Modeling Study for Pellet-Fed Extrusion-Based Additive Manufacturing to Evaluate the Impact of the Melting Efficiency

To improve the product quality of polymeric parts realized through extrusion-based additive manufacturing (EAM) utilizing pellets, a good control of the melting is required. In the present work, we demonstrate the strength of a previously developed melt removal using a drag framework to support such improvement. This model, downscaled from conventional extrusion, is successfully validated for pellet-based EAM—hence, micro-extrusion—employing three material types with different measured rheological behavior, i.e., acrylonitrile-butadiene-styrene (ABS), polylactic acid (PLA) and styrene-ethylene-butylene-styrene polymer (SEBS). The model’s validation is made possible by conducting for the first time dedicated EAM screw-freezing experiments combined with appropriate image/data analysis and inputting rheological data. It is showcased that the (overall) processing temperature is crucial to enable similar melting efficiencies. The melting mechanism can vary with the material type. For ABS, an initially large contribution of viscous heat dissipation is observed, while for PLA and SEBS thermal conduction is always more relevant. It is highlighted based on scanning electron microscopy (SEM) analysis that upon properly tuning the finalization of the melting point within the envisaged melting zone, better final material properties are achieved. The model can be further used to find an optimal balance between processing time (e.g., by variation of the screw frequency) and material product performance (e.g., strength of the printed polymeric part).