Rheology Applied in Polymer Processing

Description

This book covers a wide range of topics in polymer rheology. These are: • Basic Principles, parameters, systems and applied mathematical models used in the rheological studies. • Melt flow analysis of different non-Newtonian fluids in laminar flow, transition between laminar and turbulent flow and modified Reynolds number. • The effects of different physical and molecular parameters on purely viscous rheological response of polymer melts and solutions. • Principles of rheometery and different types of viscometers and on-line rheometers. • The static and dynamic viscoelastic response of the polymer melts and solutions, viscoelasticity, mechanical models and Boltzmann superposition principle. • Molecular structure – viscoelasticity relationship and linear and non-linear viscoelasticity. • Effects of different processes, materials parameters like temperature, fillers (micro and nano-fillers) and molecular parameters like MW, MWD. • The role of rheology in polymer processing in different equipment. • Modified power law constants and two range power law constants for a large number of polymers, rheology software program in Java, comparison of different polymer rheological models using the rheology software and answers to the problems. The book will be very useful to both undergraduate and postgraduate students, as well as teachers and practicing rheologists. Cover Half Title Title Page Copyright Page Preface Table of Contents 1. Introduction 1.1 Liquid Polymer Processing 1.2 Solid Polymers/Rubbers Processing 1.2.1 Mixing 1.2.2 Calendering 1.2.3 Extrusion 1.2.4 Moulding 1.3 Why Rheology References 2. Rheological Principles 2.1 Historical Background 2.2 Rheological Parameters 2.2.1 Stresses 2.2.2 Strains 2.2.3 Rate of Strain or Rate of Shear 2.3 Relationship Between the Rheological Parameters 2.4 Rheological Systems 2.4.1 Purely Elastic Behaviour 2.4.2 Yield Energy 2.4.3 Toughness 2.5 Purely Viscous Behaviour 2.5.1 Newtonian and Non-Newtonian Fluids 2.5.2 Time Independent Non-Newtonian Fluids 2.5.3 Pseudoplastic Fluids 2.5.4 Dilatant Fluids 2.5.5 Bingham Plastic Fluids 2.5.6 Viscoplastic Fluid 2.6 Time Dependent Fluids 2.7 Viscoelastic Fluids 2.7.1 Normal Stress Difference and the Weissenberg Effect 2.8 Rheological or Constitutive Equations 2.8.1 Two-Parameter Models 2.8.2 Three-Parameter Models 2.8.3 Four-Parameter Models 2.8.4 Generalized Rheological Correlations 2.8.5 Polynomial Rheological Relations 2.8.6 Equation for Filled Styrene Butadiene Rubber 2.9 Rheology Software Problems References 3. Fluid Flow Analysis 3.1 Laminar Flow Through Circular Cross Section 3.2 Flow Analysis Using Rheological Models 3.2.1 Power Law Model 3.2.2 Ellis Fluids 3.2.3 Binghamplastic Fluids 3.2.4 Viscoplastic Fluids 3.3 Pressure Drop-Volumetric Flow Rate Relationship 3.3.1 Estimation of True Power Law Constants 3.3.2 Energy Losses and Bagley’s Correction 3.3.3 Estimation of Bagley Correction Factor 3.4 The Wall Slip 3.4.1 Estimation of the Wall Slip Velocity 3.5 Flow between the Parallel Plates 3.6 Flow Through an Annulus 3.7 Melt Flow in a Wire Coating Die 3.8 Transition Between Laminar and Turbulent Flow 3.8.1 Ryan-Johnson Criterion 3.8.2 Hanks Criterion 3.8.3 Equivalent Diameter 3.8.4 Substitute Radius 3.8.5 Analysis of Bingham Plastic Fluid Flow 3.9 Turbulent Flow Analysis 3.9.1 Von Karman’s Approach 3.9.2 Universal Velocity Profile Approach 3.10 Flow of Viscoelastic Fluids 3.11 Turbulence Damping (Toms’s Effect) 3.12 Extensional Flow 3.13 Extensional Viscosity 3.13.1 Simple Extension 3.13.2 Biaxial Extension 3.13.3 Planar Extension 3.14. Experimental Techniques 3.15 Rheological Models for Extensional Viscosity 3.15.1 Cogswell Model 3.15.2 Binding Model 3.15.3 Gibson Model Problems References 4. Polymer Rheology—Effect of Various Parameters 4.1 Effect on Extensional Behaviour 4.1.1 Effect of Temperature 4.1.2 Effect of Strain Rate 4.1.3 Effect of Environment 4.1.4 Effect of Pressure 4.1.5 The Rate Theory 4.2 Effect on Viscous Behaviour 4.2.1 Effect of Temperature 4.3 Activation Energy of Flow 4.4 Activation Energy and Non-Newtonian Behaviour 4.5 Effect of Pressure on Viscosity 4.6 Effect of Molecular Parameters on Polymer Rheology 4.7 Solution Viscosity: Effect of Molecular Weight 4.7.1 Analysis Based on Dilute Solutions 4.7.2 Analysis of Concentrated Solutions 4.8 Effects of Molecular Weight on Polymer Melt Rheology 4.8.1 The Mechanism of Entanglement 4.8.2 Effect of Shear Rate on the Viscosity-Molecular Weight Relationship 4.8.3 Effect of Molecular Branching 4.8.4 Effect of the Molecular Weight Distribution (MWD) 4.8.5 Effect of Fillers 4.8.6 Fillers used in Rubber Compounds 4.8.7 Fillers used in Plastic Compounds 4.8.8 Mineral Fillers 4.8.9 Concentrated Suspension of Inert Fillers 4.8.10 Concentrated Suspensions of Active Fillers 4.8.11 Fiber Filled Polymers Melts 4.8.12 Nanoparticle Filled Polymers 4.8.13 Steady-Shear Rheology of Nanofilled Polymers 4.8.14 Effect of Plasticizers 4.8.15 Effect of Elastic Parameters Problems References 5. Rheometry 5.0 Viscometers 5.1 Capillary Viscometers 5.1.1 The Kinetic Energy Correction 5.2. Cone and Plate Viscometer 5.3 Concentric Cylindrical Viscometer 5.4 Dynamic Shear Rheometer 5.5 High Pressure Sliding Plate Rheometer (HPSPR) 5.6 High Pressure High Shear Rate Capillary Rheometer 5.7 Extension Rheometers 5.7.1 Rheotens Rheometer 5.7.2 CaBER Rheometer 5.7.3 Fiser Rheometer 5.7.4 Sentmanat Extension Rheometer 5.8 Rheometers In Rubber Processing 5.8.1 Moving Die Rheometer (Gibitre Instruments) 5.8.2 Oscillating Disk Rheometer 5.9 The In-Line/On-Line Rheological Measurements Problems References 6. Viscoelastic Behaviour 6.1 Static Tests 6.1.1 Stress Relaxation 6.1.2 Relaxation Modulus 6.2 Creep Test 6.2.1 Creep Compliance 6.3 Linear Viscoelasticity 6.3.1 Dynamic Tests 6.3.2 Dynamic Modulus 6.6.3 Dynamic Compliance 6.4 Dynamic Viscosity 6.5 Work Done in Cyclic Deformation 6.6 Boltzmann Superposition Theory 6.6.1 Applications of Superposition Principles 6.7 The Mechanical Models of Viscoelastic Systems 6.7.1 The Maxwell Model 6.7.1.1 Static Stress Relaxation 6.7.1.2 Static Creep Behaviour 6.7.1.3 Dynamic Stress Relaxation 6.7.1.4 Dynamic Creep Behaviour 6.8 Voigt- Kelvin Model 6.8.1 Static Stress Relaxation 6.8.2 Static Creep Test 6.8.3 Dynamic Stress Relaxation 6.8.4 Dynamic Creep Test 6.9 Other Models 6.9.1 Two Maxwell Models in Parallel 6.10 Generalized Maxwell Model 6.11 Zener Model or The Standard Linear Solid 6.11.1 Stress Relaxation 6.11.2 Creep Test 6.11.3 The Dynamic Response 6.12 Polymer Viscoelasticity 6.13 Theoretical Developments 6.13.1 Polymer Dynamics 6.13.2 High Molecular Weight Entangled Melts 6.13.3 Doi-Edwards Theory 6.13.4 The Mathematical Analysis 6.13.5 The Curtiss-Bird Model 6.14 Nonlinear Viscoelasticity Problems References 7. Viscoelastic Functions: Effect of Various Parameters 7.1 Effect of Temperature 7.1.1 Data Superposition 7.2 Effect of Molecular Weight and other Parameters 7.2.1 Effect of Cross-linking 7.2.2 Effect of Crystallinity 7.2.3 Effect of Branching 7.2.4 Effect of Copolymerization 7.2.5 Effect of the Blending 7.2.5.1 Time-Temperature Superposition (TTS) Principle Applied to Polymer Blends 7.3 Ionic Polymers and their Blends 7.4 Effect of Grafting 7.5 Effect of Fillers 7.5.1 Fillers Based on Physical Nature 7.5.2 Nano-Fillers 7.5.2.1 Nanoparticles 7.5.2.2 Properties of Nanoparticles 7.5.3 Properties Usefull in Specific Areas 7.5.4 Production of Nanoparticles 7.6 Rheology of Nanoparticle Filled Polymeric Systems 7.6.1 Effect of Alignment of Nanocomposites 7.7 Carbon Nanomaterials 7.8 Filler Characterization 7.9 Fillers for Plastics 7.10 Selection of Polymers 7.10.1 Mechanical Properties 7.10.2 Thermal Properties 7.10.3 Expansion/Contraction 7.10.4 Exposer to Chemicals 7.10.5 Environmental Considerations 7.10.6 Regulatory Approval Requirements 7.10.7 Economics 7.10.8 Other Considerations 7.11 Polymers in Automobile Industry 7.12 Polymers for Enhanced Oil Recovery 7.13 Advances in Applications of Polymers in Different Areas 7.13.1 Cyclic Olefin Polymers: Emerging Materials for Lab-on-a-Chip Applications 7.14 Polymers in Space Applications 7.15 Smart Polymers 7.15.1 Applications of Smart Polymers References 8. Rheology in Polymer and Rubber Processing 8.1 Rheology of two Roll Mill and Calender 8.2 Rheology of Internal Mixers 8.3 Rheology of Extrusion 8.4 Rubber Extruders 8.5 Vented Extruders 8.6 Coextrusion 8.7 Effect of Ratio on the Extruder Performance-Extrusion: How much L/D Do You Really Need? 8.8 Rheology of Moulding and Forming Operations 8.8.1 Injection Moulding 8.8.2 Reaction Injection Moulding 8.8.3 Compression Moulding 8.8.4 Blow Moulding 8.8.5 Rheology of Film Blowing 8.8.6 Rheology of Sheet Extrusion 8.8.7 Rheology of Melt Flow Through Dies 8.9 Pressure Drop Through the Dies 8.10 The Die Swell 8.10.1 Delayed Die Swell 8.10.2 Die Swell and Non-Newtonian Index, n 8.10.3 Effect of Length to Diameter Ratio of the Die 8.10.4 Effect of Shear Rate and Shear Stress 8.10.5 Effect of Temperature 8.11 Effect of the Solid Fillers 8.12 Effect of Molecular Weight and Molecular Weight Distribution 8.13 Relationship Between the Maximum Recoverable Deformation and Die Swell 8.14 Melt Fracture 8.15 Fiber Spinning References Annexure I-IV Annexure-I(A) Annexure-I(B) Annexure-II Rheology Program Annexure-III Annexure-IV