Flow Marks in Injection Molding of PP

Flow marks in injection moulding is quite often encountered on different type of polymers. This defects is known as successive and periodic bright and dull bands oriented perpendicular to the flow direction. Their appearances meanly depend on processing and observation conditions. This study was lead on two industrial polypropylene polymers with a simplified polished rectangular mould geometry. We show that this defect appears during the filling stage and comes from a local change of morphological and molecular orientation along the filling direction on the surface. An instability of the flow front due to a limited sliding at the contact combined to the strong changed of molecular orientation before and after the stagnation point are invoked to explain this instability.

Thermal Effects in the Numerical Simulation of the Thermoforming of Multilayered Polymer Sheets

This paper mainly treats the thermal effects during the thermoforming process while most of the previous analyses consider an isothermal deformation. A non isothermal three dimensional finite element model of the thermoforming process is proposed. It couples the thermal equations in the thickness and mechanical equations on the mean surface of the sheet. The mechanical resolution is done by a finite element method using a membrane approximation. The deformation is driven by a pressure difference through the sheet. The thermal resolution uses a one dimension finite element method in the thickness with convection or conduction at the surface and dissipation of mechanical energy. The polymer cooling is very efficient during the contact with the tools. The coupling is done by the thermal dependent rheology. The respective contributions of friction and thermal effects in the thickness of the part during the process are discussed. The model also considers a possible multilayered material, with specific rheological parameters inside each layer. The rheology of a polystyrene was measured under elongation as a function of temperature, strain and strain-rate and described by a viscoplastic law. The predictions of the model were compared with measurements on an instrumented thermoforming machine and with the local thickness of axisymmetrical parts and with 3-D parts thermoformed with the same polystyrene.

Numerical Simulation of Polymer Forging

Previous work has shown that numerical simulation does not provide a correct description of compression experiments if the rheology of the polymer in the solid state is deduced from tensile tests. Therefore, a new method is proposed for the determination of the coefficients of G'sell's constitutive equation, in order to simulate the forging process. It also gives access to a parameter characterizing the friction conditions between the polymer and the tool. It is based on isothermal compression of polymer cylinders with an appropriate geometry and on its complete interpretation by means of computer simulation using the finite element code FORGE2. This original procedure is applied to polyoxymethylene.

Influence of Stretching and Cooling Conditions in Cast Film Extrusion of PP Films

In cast film extrusion, the polymer melt is extruded through a slit die, slightly stretched in air and then cooled on a chill-roll. An important part of the present work was to study the effect of the roll temperature on the polymer crystallization in the thickness of extruded films. A thermomechanical model of the whole process taking into account the polymer crystallization was used to determine the mean stretching stress in air, local temperature, local cooling rate and local crystallization development. The morphologies in the thickness of the films were observed by optical microscopy on microtomed slices and the crystalline structures were investigated by wide-angle X-ray diffraction and DSC measurements. From DSC melting curves of thin sections it is possible to know the local crystallization temperature and to check the thermomechanical model. The model is validated and explains the influence of the roll temperature on the formation of structures and morphologies. Nevertheless neither the existence of three different zones in the thickness nor the high p phase concentration are predicted by the model, which needs new developments.

Numerical and Physical Modeling of Polymer Crystallization

Crystallization of thin polypropylene films was performed in isothermal, constant cooling-rate and mixed conditions. The experiments were first analyzed using the classical procedures based on simplified forms (Avrami, Ozawa) of the general Kolmogoroff-Avrami-Evans (KAE) theory. These analyses, which can be applied over an unusually wide transformation range, show that the crystallizations are actually 2 D. Then, a procedure has been established for the determination of the nucleation and growth parameters involved in the theoretical model presented in the first paper of this series. These parameters have been introduced into the model in order to predict the crystallization behavior in isothermal, constant-cooling-rate and mixed-conditions: transformed fraction, number of activated nuclei, final size distribution of semi-crystalline entities. A very good agreement is generally found between predictions and experimental results.

Structure Development in Injection Molding: A 3D Simulation with a Differential Formulation of the Kinetic Equations

The purpose of the present work is to introduce a crystallization law into Rem3D, a 3D code written in C++ and dedicated to the injection molding of polymers. We kept the basic hypotheses of Avrami's model and cast the kinetic equations into a differential system that is solved numerically. The variation of the density of potential nuclei with temperature is taken into account. Furthermore, the distribution of mean spherulite sizes can be deduced from the calculations. The second part of the paper is an experimental study of crystallization in well-controlled conditions (2D, isothermal or constant cooling-rate). It establishes a procedure for the determination of the nucleation and growth parameters used in the theoretical model, and gives a first validation of this model. Finally, the crystallization equations are introduced into Rem3D, in order to assess the feasibility of our new approach. Some typical results concerning the evolution of the transformed volume fraction in injection-molded parts are presented.

External Calibration in PA12 Tube Extrusion

Elongation at break is one of the major end-use properties of polyamide 12 extruded tubes. It is strongly affected by the tube microstructure and the molecular orientation resulting from extrusion conditions. Molecular orientation was characterized by X-ray diffraction and birefringence evaluation in light microscopy. Measurements were carried out on (r, z) sections obtained by polishing and microtoming. On the other hand, polymer drawing was measured on line by tracer techniques. Calibration stage was determined as the key step of the process that generates orientation in tubes: as the tube is drawn through a cylindrical calibrator under vacuum and cooled from its outside surface, calibration leads to a highly oriented zone in the twenty external microns. Calibration conditions and elongation at break have been connected through orientation level in this region. Molecular orientation was found to strongly depend on the draw ratio in the calibration tank. Finally, birefringence of the tube external layers and elongation at break were successfully correlated. Elongation at break can be enhanced by reducing orientation resulting from calibration conditions.

External Calibration in PA12 Tube Extrusion

In PA12 tube extrusion, calibration or sizing is the key step of the process that affects subsequent mechanical properties. The extruded tube is pulled through a cylindrical calibrator under vacuum. A water flow rate is applied at the inner side of the calibrator, creating a lubricant water layer at the polymer outer surface. The scope of this article is to show how this lubrication influences the elongation at break of tubes through drawing kinematics of the polymer. Lubricant water layer thickness measurements and on-line video recording have been employed to monitor the lubrication dependence of the velocity profiles from the extruder die to the end of calibrator. Velocities were measured through three independent innovative methods and thirty-two calibration conditions have been carried out to validate our work. Three main calibration parameters were found to determine the water layer thickness: the level of vacuum applied in the calibration tank, the water flow rate at the calibrator entrance, and the line speed. The influence of each parameter on lubrication level was found out. Simultaneously, the draw ratio in the calibration tank was deduced from velocity profiles. This parameter was found to affect tensile properties and to depend strongly on the level of lubrication during calibration. We showed quantitatively that rising the water layer thickness leads to a diminution of the draw ratio in the calibration tank and an increase of the elongation at break. This implies that we are now able to optimize tensile properties by fitting the main calibration parameters to improve lubrication and restrict draw ratio in the calibration tank.

External Calibration in PA12 Tube Extrusion

In polyamide 12 (PA12) tube extrusion, calibration is crucial for the major final properties such as elongation at break or burst pressure. In external calibration, the extruded tube is pulled through a cylindrical calibrator located in a water tank under vacuum. A water flow rate is applied at the calibrator inner side, creating a lubricating water layer at the polymer outer surface. A combination of a quenching and a mechanical drawing was highlighted during calibration by on-line measurements. A subsequent high molecular orientation in the outer tube layers was also featured by X-Ray diffraction and birefringence evaluation in light microscopy. Besides, influence of lubrication level in the sizing-sleeve was investigated by an estimate of the lubricating water layer and a characterization of the tube final surface state in different calibration conditions. Firstly, we quantitatively showed that rising the water layer thickness leads to a diminution of the draw ratio in the calibration tank, DrCAL (ratio between line velocity and velocity at the calibrator entrance). Excellent correlation has been found between tube superficial orientation and DrCAL: a reduced elongation of the polymer in the calibrator leads to a lower level of superficial orientation. Secondly, two kinds of surface defects were detected on the tubes by light microscopy and microtopography. At last, several correlations were featured with mechanical properties. Elongation at break was found to strongly depend on the molecular orientation resulting from calibration. Moreover, origin of rupture was investigated during tensile testing in light microscopy. We emphasized that surface defects alignments perpendicular to the extrusion initiate the rupture by creating a significant crack via coalescence of initial defects. Thus, microstructure, surface state and tensile properties can be controlled by fitting the calibration parameters to improve lubrication and reduce the draw ratio in calibrator.

Polymorphic phase behavior of perfluoroalkylated phosphatidylcholines

The polymorphic phase behavior of the F-alkyl modified phosphatidylcholines FnCmPC with Fn = CnF2n + 1 and Cm = -(CH2)m- and the physicochemical properties of their aqueous dispersions have been investigated. We show that the supramolecular assemblies formed by F4C4PC, F6C4PC, F8C4PC and F4C10PC dispersed in water consist of liposomes. F6C10PC forms, as does F8C10PC, a ribbon-like phase (two-dimensional centered rectangular lattice) at 25 degrees C, but on heating, it forms a lamellar phase. Upon cooling, the lamellar gel phase is metastable and converts slowly back into the ribbon-like phase. Analyses of the dispersions before and after heat sterilization and upon storage at 25 degrees C reveal an exceptional stability of the FnCmPC-based liposomes which contrasts strongly with that of DPPC vesicles. This enhanced stability most likely arises from the increased hydrophobic character resulting from the presence of the perfluoroalkyl tails. The gel to fluid phase transition temperature of the FnCmPCs is found to be related to the total length of the hydrophobic chain and more markedly to the length of the perfluoroalkyl tail. This phase transition is first induced by the melting of the fluorocarbon chain. Each portion of the Fn tail and of the hydrocarbon spacer experiences intrinsic changes of molecular motion with temperature. The partitioning of a lipophilic/hydrophilic paramagnetic probe between the aqueous and lipidic phases present in the FnCmPC dispersions shows that an increase in fluorophilic character results in a lower solubility of the probe in the membrane, thus reflecting a dramatic decrease of the membrane's lipophilicity.