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A Comprehensive 3D Analysis of Polymer Flow through a Conical Spiral


Extrusion Die

Article  in  Fibers and Polymers · January 2014


DOI: 10.1007/s12221-014-0084-4

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Fibers and Polymers 2014, Vol.15, No.1, 84-90 DOI 10.1007/s12221-014-0084-4

A Comprehensive 3D Analysis of Polymer Flow through a Conical Spiral


Extrusion Die
Oktay Yilmaz*, Emre Kisasöz1, F. Seniha Guner1, Cagri Nart, and Kadir Kirkkopru
Faculty of Mechanical Engineering, Department of Mechanical Engineering, Istanbul Technical University,
Istanbul 34437, Turkey
1
Faculty of Chemical and Metallurgical Engineering, Department of Chemical Engineering, Istanbul Technical University,
Istanbul 34469, Turkey
(Received February 6, 2013; Revised May 16, 2013; Accepted May 22, 2013)

Abstract: Several restrictions which are related to extruder machinery and nature of process material exist in the design of
plastic extrusion dies. To this respect, it is very important to consider design criteria and limitations in order to operate
extrusion dies at desired production rate and temperature. In the current study, flow field characteristics through a conical
spiral mandrel die are analysed in detail by 3D Computational Fluid Dynamics (CFD) simulations. The effects of operating
conditions such as production rate and temperature on pressure drop through the spiral mandrel die and the occurence of melt
fracture are investigated. The temperature dependent viscosity versus shear rate data for grade QB79P (CarmelTech)
polypropylene (PP) melt under study are measured by use of rotational and capillary rheometers. Stress terms in the
momentum equations are modeled by Generalized Newtonian Fluid (GNF) Model. For this, Bird-Carreau Model is employed
as the viscosity model for the polymer melt. 3D CFD analyses provide comprehensive data and understanding with regard to
flow behaviour through complex extrusion dies.
Keywords: Conical spiral mandrel die, Polymer extrusion, CFD, Generalized newtonian fluid model

Introduction help mixing of polymer melt. Number of layers in a coextrusion


process can be increased by adding identical conical spiral
Spiral mandrel dies which are used in coextrusion heads mandrel die geometries such as the one in Figure 1, con-
offer some benefits to the manufacturers in the plastics secutively. Therefore, diameter of a coextrusion head which
industry. Spiral mandrel dies provide good thickness uniformity consists of conical spiral mandrel dies is smaller than that of
with a broad range of processing parameters (raw material, a coextrusion head which consists of cylindrical spiral
throughput and temperature), short residence times (chemical mandrel dies. Coat-hanger dies can be employed in conical
property or colour changes), low pressure drop and good spiral dies in order to distribute the polymer melt uniformly
thermal control in film, sheet and pipe production. They through the entrance section of spiral grooves. The conical
eliminate the weld lines due to spider legs, which support the spiral mandrel die shown in Figure 1 can be split into three
mandrel in the annular die of conventional dies. For this sections. The first section is the pre-distribution system
purpose, spiral grooves are typically machined in the mandrel. which consists of cylindrical and rectangular channels. The
The spiral grooves distribute the melt circumferentially to second one is the coat-hanger type distributor and the last
increase the uniformity of the velocity at the die exit and one is the spiral die section. Design of the distribution
system is crucially important in order to provide uniform
flow through the spiral die inlet. Thus, the spiral die at the
last section can be operated with maximum performance in
terms of balanced velocity distribution at the die exit.
Researches on coat-hanger dies [1-4] and spiral dies [5-11]
have been performed for several decades. In these early
studies, flow inside the spiral and coat-hanger die was
analyzed by one dimensional or two dimensional simplified
approaches. These approaches can be divided into two groups.
The analytical approaches are used for the optimization of
extrusion die geometries in the first group [2-4]. The polymer
melt flow in extrusion dies is generally slow and is of laminar
character. Therefore, one dimensional flow (lubrication
approximation) through the rectangular and circular channels
Figure 1. The conical spiral mandrel die under investigation. can be assumed. Mathematical expressions for the extrusion
die geometries such as distribution channel form of a coat-
*Corresponding author: yilmazo@itu.edu.tr hanger die are obtained by use of analytical approaches. In

84
Polymer Flow through a Conical Spiral Extrusion Die Fibers and Polymers 2014, Vol.15, No.1 85

the second group of design methods, electrical network melt fracture. A comprehensive analysis is carried out on the
approach is employed for obtaining flow distribution in flow field characteristics through the die in terms of low
extrusion dies [1,6,7,9]. In this method, flow channels of limit of wall shear rate, upper limit of shear stress, flow
extrusion die are divided into control volumes and analytical uniformity inside the die and pressure drop through the die
expressions in [18,20] are used for flow through these which are the crucial restrictions for the design of spiral
control volumes which have simple shapes such as circular mandrel dies.
and rectangular. Flow distribution through extrusion dies can
be determined by solving the resultant system of equations. Materials
The die performance can be optimized by changing the
geometric parameters until satisfactory flow distribution is A polypropylene random copolymer QB79P from CarmelTech
achieved. Analytical approaches and electrical network methods with a melt flow rate (MFR) of 0.28 g/10 min (230 oC, 2.16 kg)
are both relatively easy and fast methods to implement die was used in the present work to investigate the flow field
design. Hence, these techniques are still very useful for the characteristics in the conical spiral mandrel die. The density
preliminary die design. However, a full three-dimensional was measured by capillary rheometer according to ASTM
simulation of flow in spiral mandrel dies is required for an D3835-08 standard for the PP melt and by Archimedes'
accurate analysis and obtaining flow field characteristics in principle according to ASTM B962-08 standard for the solid
detail. In contrast to analytical and other simplified approaches, PP. The densities of the material at room temperature, 210 oC,
nonisothermal processes and some rheological characteristics 230 oC, 260 oC are 910, 790, 783 and 772 kg/m3, respectively.
of polymer melts such as viscoelasticity, elongational viscosity Shear viscosity versus shear rate data for the polymer melt
can be considered in CFD simulations [12-15]. Zatloukal et were measured by use of an Anton-Paar Physica MCR 301
al. [12] performed CFD simulations for a flat spiral mandrel model rotational rheometer with a 25 mm diameter parallel
die. When the viscoelastic properties of the polymer melt are plate geometry and a capillary rheometer using capillary dies
included in numerical simulations, velocity distribution at of 10, 20 and 25 mm lengths with 1 mm diameter hole for
the die exit is not changed. Hence, Zatloukal et al. [12] three temperature values. The Bagley and Rabinowitsch
concluded that incorporating only shear thinning behavior of corrections [17] are applied to the capillary rheometer raw
the polymer melt used in their study is satisfactory from the viscosity data. The Bird-Carreau viscosity model (equation
point of view of velocity distribution at the die exit. (10) parameters of the material are given in Table 1.
Skabrahova et al. [13] studied effects of non-symmetrical η0
inputs of temperature and mass flow rate prior to the spiral η(γ· ) = ------------------------------------
- (1)
[ 1 + ( λγ· ) ]
n ( 1−n )/2
die on velocity and temperature distribution at the die exit.
The die performance was affected negatively from feeding Here η and γ· are shear viscosity in Pa.s and shear rate in
of the spiral die entrance non-uniformly. Sun and Gupta [14] sec-1, respectively. η0, λ and n are zero shear viscosity in
carried out finite element method (FEM) simulations for Pa.s, relaxation time in sec and dimensionless power-law
polymer melt flow through a cylindrical spiral mandrel die index of polymer melt, respectively.
with star distribution system. In their study, the effects of
elongational viscosity on flow field characteristics were Die Geometry
analyzed. It was concluded that including the elongational
viscosity of polymer melt in CFD simulations resulted in an The geometric parameters of the spiral die section in
increase in pressure drop through the die. On the other hand, Figure 1 and Figure 2 are determined by use of analytical
velocity distribution was not affected. Wanli and Xinhou method suggested by Rauwendaal [7]. The curvature of the
[15] analyzed the effects of some geometric parameters of a spiral die is neglected in this method. Flow is assumed to be
coat-hanger die on the die performance with respect to exit isothermal and polymer melt viscosity obeys the power law
velocity distribution and residence time by non-isothermal model. Flow through the spiral die is split into two parts. The
CFD simulations. Huang et al. [16] performed FEM simulations first part flows through spiral groove and the second part
for a coat-hanger die which was designed by using an flows through annular channel as flow leaks from spiral
analytical method introduced in literature [2]. It is shown grooves. It is assumed that these two split flows do not affect
that the analytical design method was successful in terms of each other at the interface. Flow through the spiral groove is
flow balancing at the die exit. Nevertheless, stagnation zones
in the die and the process material effect on the flow Table 1. The Bird-Carreau model parameters of the polymer melt
uniformity could only be predicted by CFD simulations. 210 oC 230 oC 260 oC
In the present study, the effects of production rate and
ηo (Pa) 42655 33916 18587
temperature on the design of the conical spiral die in Figure 1
are investigated by FEM simulations with respect to maximum λ (s) 2.13 2.71 2.08
pressure to be supplied by extruder and limit shear stress for n (−) 0.328 0.370 0.390
86 Fibers and Polymers 2014, Vol.15, No.1 Oktay Yilmaz et al.

Figure 2. Section drawing of the conical spiral mandrel die.

assumed to be pressure flow in a rectangular channel of


height H and width W with use of a shape factor. Flow through
the annular channel is a pressure flow in slit channel. Pressure
Figure 3. The computational domain for the conical spiral mandrel
is assumed to be constant at the plane perpendicular to the
die.
spiral die axis. Flow distribution through the die can be
calculated by use of analytical expressions in a step-wise
manner along spiral grooves. Spiral die design is optimized are meshed by tetrahedral elements. Thus, it was achieved a
by solving the flow problem iteratively with the change of decrease in mesh number and computational time and an
geometric parameters until satisfactory die performance is increase in computational accuracy. The computational domain
achieved. has 367112 cells in total with hexahedral dominant elements,
The die has 12 equally spaced spiral grooves with φ=15 o providing good mesh quality. Flow in the conical spiral
helix angle at the beginning of the spiral, which gradually mandrel die is incompressible, as it is the case for most of
increases along the spiral. The winding angle of the spiral the polymer extrusion processes where pressure is lower
grooves is 180 o. Initial spiral groove height Ho is 12 mm and than 350 bar [19] and flow is of laminar character due to the
spiral groove width W is 8 mm. Initial annular channel very low velocity of polymer melt (Reynolds Number <<1).
thickness δo is 2 mm and this increases through the die Due to the very high viscosity of the polymer melt, inertial
linearly with an angle of β=1 o. Half cone angle α of the and gravitational forces are negligible and this yields a
conical spiral mandrel die is 30 o. balance between viscous and pressure forces. CFD simulations
The geometric parameters of the coat-hanger type distributors are performed for isothermal conditions assuming that die
in Figure 1 are optimized by an inverse design technique temperature is controlled at a fixed value of 230 oC. Stress
which involves electrical network approach [1] for the flow terms in the momentum equations are modeled by Generalized
paths in the distributor. Four coat hanger dies are used to Newtonian Fluid (GNF) Model [20]. For this, Bird-Carreau
distribute the polymer melt to the spiral die. The die land Model in equation (1) is employed as the viscosity model for
thickness h is 4 mm and the die land length at the die center the polymer melt. The governing equations of the flow are
yo is 50 mm. The coat-hanger die has rectangular distribution given below.
channels. The outer diameter D of the conical spiral mandrel ∂vi
die is 500 mm. ------- = 0 (2)
∂xi
Numerical Simulations ∂τ
∂p- -------
------ = ij- (3)
∂xi ∂xj
CFD simulations are carried out by use of PolyFlow [21],
a commercially available widely used package as in [22], τ = η(γ· )γ·
ij ij (4)
which uses finite element method. The mesh generated for
the flow domain of the conical spiral mandrel die is depicted Here, η is the viscosity function in equation (1) and γ· ij is
in Figure 3. A cylindrical annular channel with 50 mm the strain-rate tensor components. vi, p and τij are velocity
length is added to the spiral mandrel die exit in order to components in m/sec, hydrostatic pressure in Pa and stress
obtain fully developed flow at the die exit. The computational tensor components in Pa, respectively. The flow has fully-
domain is divided into numerous sub-volumes in order to developed conditions at inlet and exit boundaries in CFD
mesh with hexahedral elements. A few complex sub-volumes simulations. No-slip boundary conditions are applied at the
Polymer Flow through a Conical Spiral Extrusion Die Fibers and Polymers 2014, Vol.15, No.1 87

Table 2. The mass flow rates through the conical spiral mandrel die
in CFD simulations
.
Mass flow rate, m (kg/h)
29.2
58.5
87.7
116.9
146.1
175.4
204.6
233.8

die walls. Mass flow rates to be supplied to the conical spiral


mandrel die are given in Table 2.

Results and Discussion

Analysis of Flow Field in the Conical Spiral Mandrel Die


A CFD simulation for a specific process condition is
performed in order to evaluate in detail the flow field variables
in the conical spiral mandrel die specifically designed for
Figure 5. The velocity vectors (a) from coat-hanger distributor
use in a coextrusion die in order to produce three-layered through the spiral die section (b) from spiral die section.
pipes. Each conical spiral mandrel die forms one layer of the
pipe. The pipe diameter and thickness will be 32 mm and
3.6 mm, respectively. Each layer of the pipe will have the die section. The velocity vectors in spiral grooved die are
same thickness. In this case, mass flow rate for one layer is shown in Figure 5. After the coat-hanger die transferred the
116.9 kg/h for a 20 m/min pipe production rate. Process polymer melt to the spiral die section, large amount of the
temperature is set as 230 oC for a typical process temperature fluid particles is in the spiral grooves initially. Towards the
in PP pipe production. exit of the spiral die, the spiral groove height decreases and
The streamlines through the spiral mandrel die are shown thickness of the annular channel increases. As a result, some
in Figure 4. It can be seen from this figure that the polymer fluid particles leak from spiral grooves to the annular
melt is distributed to the spiral die inlet by coat-hanger dies. channel steadily. All fluid particles flow along the main flow
Mixing effects of the spiral die can be observed, as the direction after the spiral die. There is an interaction between
polymer melt has angular velocity component in the spiral the flow in annular channel and the flow in spiral groove as
seen in Figure 5, this phenomenon can not be taken into
account in analytical methods [5-7] used for solving flow
distribution in spiral dies. The material flow are entirely in
the main flow direction between two spiral grooves in the
annular channel.
The deviation of the local velocity from the mean velocity
with respect to the angular position in the annular channel at
the spiral die exit is shown in Figure 6. The maximum
deviation of the local velocity at the spiral die exit is about
±1 %. The analytical method suggested in [7] and adapted
for the present die calculated maximum deviation about
±2.5 % from the mean velocity at the spiral die exit. The rest
of the die (die land) after the spiral can eliminate the
deviations from the mean velocity at the spiral die exit up to
10 % [8]. Hence, it can be said that the analytical method
used for the design of the conical spiral die is successful for
providing uniform velocity distribution at the die exit.
Figure 4. Stream lines through the spiral mandrel die. Figure 7 depicts the contours of velocity magnitude and
88 Fibers and Polymers 2014, Vol.15, No.1 Oktay Yilmaz et al.

Figure 6. Deviation of the local velocity at the spiral die exit with
respect to the average velocity at this cross section.

Figure 8. Pressure distribution through the conical spiral mandrel


die.

structure and colour [19]. The minimum shear rate takes


place in the first spiral groove as seen in Figure 7 and its
value is around 8 sec-1. Therefore, consideration of low limit
of shear rate is necessary in the design process of spiral dies.
Pressure distribution inside the flow domain of the conical
spiral mandrel die is depicted in Figure 8. As the flow cross
sectional area of the die decreases towards the end of the die,
pressure gradient increases. The pressure drop through the
die head should not exceed the extruder maximum pressure
in order to operate the die at the specified production rate
and process temperature. Pressure drop from inlet to the exit
of the coat-hanger die in Figure 1 are calculated 18.52 bar by
electrical network method [1] and 20.74 bar by CFD. Pressure
drop from spiral groove beginning to spiral groove end is
Figure 7. Contours of (a) resultant velocity and (b) shear rate at the estimated 49.78 bar by analytical method [7] and computed
spiral die cross section which is parallel to the main flow direction.
42.29 bar by CFD. The interface between spiral grooves and
annular channel in spiral die section from which flow leaks
shear rate in spiral die cross section. Both of these variables is assumed to be solid wall in the analytical method [7] for
have similar variations in the flow domain. The magnitudes spiral die. Hence, analytically estimated pressure drop through
of the variables in spiral grooves are relatively low due to the spiral die is larger than that computed by CFD.
wider cross section. Between two spiral grooves in the Malekzadeh et al. [11] reported that Rauwendaal’s method
annular channel, the shear rate and velocity are relatively [7] solution agrees well with FEM results for pressure drop
high due to narrower cross section. As the diameter of the through a flat spiral die. Analytical approaches and electrical
conical spiral die and depth of the spiral grooves decrease in network methods seem indispensable tools for predicting die
the main flow direction, shear rate and velocity continuously performances expeditiously.
increase in magnitude. The shear rate in spiral mandrel die When the polymer melt is exposed to shear stresses above
walls is desired to be greater than 5 sec-1. Providing wall a certain critical limit at the die walls, especially along the
shear rates over the low limit (5 sec-1) is vitally important for die land close to the die exit, the plastic material leaves the
filled polymer melts which have yield stresses to start flowing. die exit having irregular or wavy surfaces. This phenomenon
In the case of very small shear rates, the residence time of is called melt fracture in the literature [19]. The melt fracture
the material through the die will be long and polymer melt limit is mainly dependent on the processed polymer. However,
may be thermally degraded leading to change in its chemical this limit can be increased by adding plasticizers [19]. In the
Polymer Flow through a Conical Spiral Extrusion Die Fibers and Polymers 2014, Vol.15, No.1 89

Figure 10. The characteristic curves of the conical spiral mandrel


die when it is operated by PP (QB79P).

∆P = Rm·
n
(5)
Here, n is the power-law index of the polymer melt for
shear viscosity at process temperature as seen in Table 1. R
is the flow resistance of the spiral mandrel die and is
Figure 9. Shear stress distribution at the die walls. dependent on the die geometry, the process material and
temperature. This relation is of the same form as that for the
simple shaped dies such as circular, slit or annular channels
present study, melt fracture limit of the PP (grade: QB79P) is
as suggested in [18]. The pressure drop is proportional nearly
determined by capillary rheometer measurements and its
one third power of the flow rate. For process temperature of
value is 112000 Pa. The shear stress distribution at the die
210 oC, when the mass flow rate is increased from 29.2 kg/h
walls is shown in Figure 9. The wall shear stresses in the
to 233.8 kg/h, the pressure drop through the die increases
blue-circled regions (around the spiral die exit and corners in
from 101 bar to 202 bar. This is only two times increase in
the flow domain) in Figure 9 exceed the melt fracture limit
the pressure drop against 8 times increase in the flow rate. In
of the PP under study. The wall shear stress values of
contrast, pressure increase will be 8 times for an 8 times
complex flow channels such as corners cannot be calculated
increase in flow rate in laminar flow of a Newtonian fluid.
with analytical approaches several of which can be found in
This is very beneficial for the point of view design of the
[18] developed for the design of extrusion dies. Hence, CFD
plastic extrusion dies because pressure drop does not change
analyses are to be carried out in order to examine the flow
too much in a broad range of production rates.
field characteristics of polymer melts in complex flow channels.
The maximum shear stress at the die walls is given for
Besides, the wall shear stresses are relatively high in the
various mass flow rates and the processing temperatures in
annular channel between spiral grooves due to smaller cross
Table 3. The risk of flow instability increases for low
sections in Figure 9. High wall shear stresses at walls can
temperatures and high mass flow rates as can be seen from
only be reduced by decreasing the production rate or increasing
CFD simulation results in Table 3. As the temperature decreases,
the die temperature for an existing die design, but in this
the viscosity of the polymer melt and resulting maximum
case production cost increases. Thus, the cross sections of
the die should be determined carrefully, in order to operate Table 3. Maximum wall shear stress through the die for different
the die at the desired temperature and production rate process temperatures and mass flow rates
without having any process limitations.
Maximum wall shear stress (Pa)
The Effects of Extruder and Process Material Limita- Mass flow rate (kg/h) 210 oC 230 oC 260 oC
tions on Operating Conditions of Extrusion Dies 29.2 085316 063300 42358
CFD simulations are performed for different mass flow 58.5 109060 082827 56325
rates given in Table 2 and for temperatures of 210, 230 and 87.7 125130* 096303 66229
260 oC. The throughput-pressure drop curves of the conical 116.9 137618* 107304 74064
spiral mandrel die are shown in Figure 10 for different 146.1 148265* 116546* 80979
temperatures. Power-law model are fitted for each experimental 175.4 157952* 124537* 87099
data set and the related model parameters are given in Figure 204.6 165320* 132046* 92350
10. The relation between the pressure drop through the conical 233.8 173296* 138604* 97172
spiral mandrel die and mass flow rate is of the following
*Maximum wall shear stress exceeds the limit shear stress for melt
form. fracture.
90 Fibers and Polymers 2014, Vol.15, No.1 Oktay Yilmaz et al.

wall shear stress increase. Therefore, the die must be operated production rates with relatively small changes in extruder
with a high temperature in order to reach high production power.
rates. In this case, operating cost increases due to increasing
energy consumption for additional heating. Consequently, Acknowledgements
designing of flow channels of the spiral mandrel die by taking
into consideration of material property (melt fracture) is of We gratefully acknowledge the financial support of
critical importance for extrusion with desired production rate Ministry of Science, Industry and Technology of the
at a specific processing temperature. Turkish Republic and Mir R&D Ltd. Co., through grant
number: 00309.STZ.2008-2.
Conclusion
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