ALPlastics

oyonnax 10/07/13

Plastication in injection moulding :

Principles, Numerical modeling
and in line Visualisation
Yves Breaux1,a , Jean-Yves Charmeau2,a , Thuy Linh Pham2,a
Jean Balcaen2 , Mal Moguedet3 , Richard Apaloo

BACK

LaMCoS UMR5259, INSA-Lyon

IMP@INSA UMR5223, INSA-Lyon

PEP,Centre Technique de la Plasturgie

Filire Gnie Mcanique Procds Plasturgie, INSA-Lyon

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Outline
Polymer Processing : Challenges
Injection Moulding
Plastication in injection Moulding
Physics
Visualization
Modelling
Fibre breakage
Flow in screw channel

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Thermo-Plastics Processing :
Heat transfer

solide
pellets, powder

Mechanics
melting

Challenges

Physics, Heat transfer

solidification

liquid

aspect

solid
part

molten polymer

plastication

flow and shaping

moulding

temperature, rpm

pressure, flow rate, viscosity

Tcryst., Tmould

geometry
mechanical properties

shear rate, Tfusion

Processing bears an impact on thermo-mechanical history from material to part

Processing parameters 6= Physics variables
Analysis on the product (consequences) Physics causes
Instrumented machine 6= Scientific instrument

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Injection-Moulding
Cyclic Process : widely used for making thin parts (not hollow)

2 metering

3 injection

1 plastication

4 packing

6 cooling

5 holding

7 part ejection

Research groups main interests :

Plastication & Flow in screw barrel system
Surface defects of injection-molded parts not today

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Visualisation
Looking for a visualization device :
Scale relevant to polymer processing machines
Applicable to screw barrel units
continuous in line flow visualisation : 3D, no blind spots
Automated particle tracking ( particle : pellet, fibre, fluorescent tracer )
Post-treatment of position : Velocities

Literature review
Extruder with glass windows to observe solid bed motion and plasticising:
Wong (1999) [WLLZ99], Gao (2000) [GJC00].
Transparent barrel with (one or two ) video cameras to record a particle motion:
Campbell 1992 [CSF92], Choo 1980 [CNP80].
Magnetic Resonance Imaging (MRI) on a non-metallic barrel and screw unit :
Amin (2003) [AHH+ 03], Agemura (1995) [AKM95].
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Visiovis Data acquisition

firewire

camera V1
computer H

mobile rack

led

calibrator

usb

camera H2

clock

camera H1

particle
firewire

led

usb

computer V

Barrel : PMMA

barrel

camera V2

Fluorescent Particle (0.4 mm)

Screw D400.4 mmlength 6D continuously monitored by 2 over 4 cameras

Silicone oil 100Pas

recording two sets of 2D pathlines

[Mog05]M. Moguedet. Dveloppement dun outil daide la conception et au fonctionnement dun ensemble vis/fourreau
industriel -Application linjection de thermoplastiques chargs fibres de verre longues. PhD thesis, INSA-Lyon, 12
Dcembre 2005
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Visiovis : Pathlines reconstruction

Data sets of 2D positions are : filtered from noise, corrected from refraction combined to give a 3D pathline

Particle moving down and up the channel : slow near the barrel fast near the screw root

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oyonnax 10/07/13

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Visual Barrel design

Standard size barrel with :
3 optical glass windows
3 plane surfaces for visualization
and lightening (laser sheet option)
3 cameras monitoring :
plastication , flow charge dispersion

[Pha13]T.-L. Pham. Plastification des polymres fonctionnels et chargs. PhD thesis, INSA-Lyon, 2013. en cours
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Transparent Barrel Plastication

channel

flow

flight

solid bed

Solid bed width increases with screw frequency

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melt pool

Lateral film increases when screw is idle

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Plastication
hopper
pellets
solid bed

barrel

screw
rpm

nozzle
melt film

melt pool

Pellets melt along the screw following Maddock/Tadmor model : [Mad59, TDK67]
Solid bed of compacted pellets with continuously decreasing width
Molten polymer film at the barrel inner surface ...
... continuously wiped by the screw flights ...
accumulates in a melt pool
Unresolved issues :
solid bed permeability [NOF04], Solid bed velocity and acceleration, [FkSN82], lateral melt films
[Lin85]?

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Plastication in extrusion: Tadmors model

Tb

fourreau

=
mlt

Vbx

1111111111
0000000000
Vsy
0000000000
1111111111
0000000000
1111111111
0000000000
1111111111
Tm
0000000000
1111111111
X
0000000000
1111111111
0000000000
1111111111
0000000000vis
1111111111

KVrn+1 1n
Br =
km (Tb Tm )
a(T b Tm )
A =
n

Fusion : contact and melt renewal

Thermo-dependent power-law viscosity =
K exp(a(T Tm )) n1

Melt film thickness :

Solid bed : width X, velocity Vsz . Channel H,

W . Mass flow rate mlt :

BACK

Tm ) (1 + Br U1 ) X
Ethlpy

dimensionless numbers : Br self heating (viscous dissipation), A Thermo-dependence

=
mlt

v
u
u Vbx U2 m km (Tb
t

mlt
=
m Vbx U2 (A)

d
(s HXVsz )
dz

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Plastication : Results
Solid fraction X/W along the screw length :
1

Feed

0.9

Metering

Transition

Solid bed Width / Channel Width

Solid bed Width / Channel Width

0.8
0.7
0.6
0.5

Pryltex

0.4

PP

0.3

HDPE

0.2

rpm 40

0.1

screw 90mm

Feed

0.9

10

12

N screw/turn

14

16

18

Metering

0.8
0.7
0.6
0.5
0.4

screw 90mm

0.3

Pryltex rpm 40 Tb 240C

rpm +50%

0.2

rpm +50% BP +50%

0.1

Transition

Tb +50C
2

10

12

N screw/turn

14

16

18

Plastication length :
increases with shear rate (increase viscous dissipation) (at a given throughput)
decreases with higher screw rpm
higher barrel temperature conflicting : increases conduction but decreases viscosity

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Plastication in Injection Moulding

At the beginning of rotation the solid bed reorganises

Specifics :
not continuous (steady state) but cyclic

1
1
0,9
0,9
0,8
0,8
0,7
0,7
0,6
0,6
0,5
0,5
0,4
0,4
0,3
0,3
0,2
0,2
0,1
0,1
0
0

sequence of steps : rotation (extrusion-like), dwell

and forward injection
melting depending on the time when pellets enter
feed zone
Modelling Nunns approach [Nun86]
screw forward motion: additional melting (no solid
bed motion)
2
km (Tb Tm ) + S inj
X = X0 exp tinj
Hm Ethlpy

Injection
Extrusion

10

10

15

15

20

20

melting length shorter

residence time is much longer

dwell : film thickness increases by transient con- [Apa05] R. E. Apaloo. Plastification en injection. simplast.
Masters thesis, Insa-Lyon, GMPP, 2005
duction
s

BACK

km (Tb Tm )tdwell
+ 0
s

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Fibre Breakage
Fibres anchored at one end in solid bed, submitted at the other end to intense shear
Vbx

fourreau

111111
000000
0
1
d
000000000
111111111
000000
111111
0
1
000000000
111111111
000000
111111
0
1
00000000000000
11111111111111
000000000
111111111
000000
111111
00000000000000
11111111111111
000000
111111
00000000000000
11111111111111
00000000000000
11111111111111
lit solide
00000000000000
11111111111111
00000000000000vis
11111111111111

000000
0
1
111111
l

Mittals [MGS88] model extended to power-law fluid :

applied

Z l
128 3n KVrn
An1
(1 exp(Ax))x
=
dx
d3
(exp(A) 1)n 0
log( 7.4
)
Re

depends on film thickness , shear rate, viscosity K, fibre diameter d and orientation l
Fibre breaks when applied > max
New layer of fibres uncovered as the solid bed is melting
Fibre length distribution obtained starting from a uniform distribution with random orientation

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Fibre breakage in extrusion

Screw extraction and fibre length measurement Gupta [GMS+ 89]
Comparison between measured and calculated mass (Lw) and number(Ln) averaged fibre length
P

ni L i
Ln = Pi
i ni

80

Lw exp = 3.85 mm
Lw calc = 3.60 mm

35
fraction en masse %

Ln,Lw (mm)

40

Ln exp
Ln calc
Lw exp
Lw calc

70
fraction en nombre %

10

ni L2i
Lw = P
i ni Li
P

30
25
20
15

Ln exp = 1.05 mm
Ln calc = 1.10 mm

60
50
40
30

10

20

10

10
N D_Vis

15

20

3 4 5 6 7 8
longueur fibre (mm)

3 4 5 6 7 8
longueur fibre (mm)

PP LGF 9mm on a 38mm diameter screw

agreement is good at low rpm, less so at higher rpm
[Mog05]M. Moguedet. Dveloppement dun outil daide la conception et au fonctionnement dun ensemble vis/fourreau
industriel -Application linjection de thermoplastiques chargs fibres de verre longues. PhD thesis, INSA-Lyon, 12
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Dcembre 2005

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Flow in a screw channel

Flow provoked by screw rotation and back pressure of the die downstream

Vx

N
V

Vz

z
W

Parallel Plates Model :

Rotating barrel around a static screw : steady-state problem
Unwound Channel: H  RB : no direct effects of torsion and curvature
High aspect ratio: H  W : no direct effects of screw flights

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Single screw throughput calculations

Pressure

BackPressure = Palim + Pcomp + Pmeter

BackPressure

Screw Diameter

Hfeed

m
= m Qliq + s Vsz HX

Q?

rpm

Hmeter

Lfeed

Lcomp

Lmeter

m Q

1D relationship between flow rate and local pressure gradient for power-law fluids:

3 zone screw viewed as a melt pump where :

screw forward displacement (drag flow),

Q =

Vbz W H
|6G|s sgn(G)f ()
(1 + s)(1 + 2s)

G =

H n+1 (z) dP
6KV0n dz

pressure gradient in the screw channel.

Pressure development begins at atmospheric
pressure and ends at Back pressure imposed
on the screw

BACK

W X
W
HX
Halim Walim

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Throughput and Pressure profiles

70

PS Styron, T 211C
PC Lexan, T 285C

60

30

pressure (MPa)

80

pressure (MPa)

90

modele Debit (kg/h)

100

exp. Md=32.2 kg/h

25

20

35
30

20

50

15

10
rpm=40

10%

rpm=100

10

model Md=35.9 kg/h

30

exp. Md=99.6 kg/h

25

15

40

40

model Md=103.4 kg/h

5

model + plast. Md=35.5 kg/h

20

essai Debit (kg/h)

20

30

40

50

60

70

80

90

100

10

15

20

25
30
N screw turn

model + plast. Md=90.8 kg/h.

0

10

15

20

25
30
N screw turn

Throughput :
1. Screw geometry
2. Polymer Rheology
3. Plastication length
[BCM09] Y. Breaux, J.-Y. Charmeau, and M. Moguedet. A simple model of throughput and pressure development for
single screw. Journal of Material Technology and Processing, 209(1):611618, 2009

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Aims
Specific effects of helical geometry on flow of viscous and viscoelastic fluid

Hypotheses
Incompressible fluid in steady-state creeping flow
Screw channel :
constant depth and pitch
curvature, torsion
flights
rectangular cross-section
No leakage flow through barrel/screw clearance
Perturbation method
pressure & drag flow of viscous fluids
pressure flow of viscoelastic fluids

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Rectangular helical screw channel

z
r

2P
W/2

B
R

H/2

Geometry

BACK

Dimensionless Numbers

Hydraulic Diameter

Curvature

Torsion

Helix Angle

tan()

2HW
H +W
R
2
R + P2
P
2
R + P2
P
R

page 22 

W
H

tan()

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Applicability

Visiovis Extruder (pumping zone)

Aspect ratio

6.9

21.8

Curvature

0.44

0.15

Torsion

0.16

0.05

0.36

0.33

tan()

Curvature  and torsion are small but not negligible dimensionless parameters
Aspect ratios are very large

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Overview
Fluid

Flow type

Flow direction

Helicity

viscous

drag

down-channel w

curvature 

viscoelastic

pressure

cross-channel u, v,

torsion

Ducts

y
Z

Z
y

Y
X

Tore ()

BACK

Helix (, )

page 24 

Straight twisted duct ()

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Pressure flow/Newtonian fluid

w0 + 2 w2

w0
=1

0.5

0.5

0.5

0.4

0.4

0.4

0.3

0.3

0.3

0.2

0.2

0.2

0.1

0.1

0.1

-0.5 -0.4 -0.3 -0.2 -0.1 0

outer wall <--- x

-0.4

-0.3

-0.2
-0.1
outer wall <---

0
x

0.1
0.2
--> inner wall

0.3

0.4

-0.1

-0.1

-0.2

-0.2

-0.2

-0.3

-0.3

-0.3

-0.4

-0.4

-0.4

-0.5 -0.4 -0.3 -0.2 -0.1 0

outer wall <--- x

-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall

-0.5 -0.4 -0.3 -0.2 -0.1 0

outer wall <--- x

-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall

0.5

0.5

0.5

0.4

0.4

0.4

0.3

0.3

0.3

0.2

0.2

0.2

0.1

0.1

-0.5

-0.1

-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall

= 1/5

w0 + w + 2 w2

0.1
y

-0.1

-0.1

-0.1

-0.2

-0.2

-0.2

-0.3

-0.3

-0.3

-0.4

-0.4

-0.4

-0.5
0.5

-0.5
0.5

-0.5

-0.4

-0.3

-0.2
-0.1
outer wall <---

0
x

0.1
0.2
--> inner wall

0.3

0.4

-0.5

-0.4

-0.3

-0.2
-0.1
outer wall <---

0
x

0.1
0.2
--> inner wall

0.3

0.4

-0.5
0.5

Curvature : max velocity shifting towards the inner wall

Torsion : max velocity decreases

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Pressure flow, curvature effects

w/w0av

2.5

1.5

w plfw, y = 0
1

w plfw, x = 0
w0 + w + 2 w2 , y = 0
w0 + w + 2 w2 , x = 0
w0 + w , y = 0

0.5

0
0.5

x, y
0.4

0.3

0.2

0.1

0.1

0.2

0.3

0.4

0.5

 = 0.66, = 0, = 0.5
large shift of the down-channel velocity w towards the inner wall (deep channel)

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Pressure flow, torsion effects

Down-channel velocity w

Cross-channel velocity u, v,

0.25

1.8

0.2

1.6

0.15

1.4

u/w0av

w/w0av

1.2
1

w0 + 2 w2 , y = 0
w0 + 2 w2 , x = 0
w0 , y = 0
w0 , x = 0
w plfw, y = 0
y
w plfw, x = 0

0.6

0.4
0.2
0
0.5

0.4

0.3

0.2

0.1

0.1

0.8

0.1

0.2

u plfw, y = 0.25
u , y = 0.25
u plfw, x = 0
u , x = 0

0.05
0

u plfw, x = 0.25
u , x = 0.25

0.05
0.1
0.15
0.2

0.3

0.4

0.5

0.25
0.5

x, y

0.4

0.3

0.2

0.1

0.1

0.2

0.3

0.4

x, y

= 2, = 0.6,  = 0

= 5, = 0.15,  = 0

Narrower w profile

Secondary flow created

w0av when > 1
u scales like 1+
4

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0.5

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
-0.2
-0.3

-0.5
0.1 0.2 0.3 0.4 0.5

drag pressure flow - W0dp - aspect 5

0.5

drag pressure flow - Wdp - aspect 5

0.5

0.4

0.3

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
-0.1
-0.2
-0.3

0.3

0.2

0.4

0.2

--> inner wall

outer wall <---

-0.5 -0.4 -0.3 -0.2 -0.1

--> inner wall

-0.5
0.1 0.2 0.3 0.4 0.5

-0.4

-0.3

-0.2

-0.1

0 y

0.1

w0d GP w0

0.1

0 y

-0.1

-0.2

-0.3

-0.5 -0.4 -0.3 -0.2 -0.1

-0.4

outer wall <---

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oyonnax 10/07/13
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Drag & pressure flow, down-channel velocity w

Visiovis design = 7 = 0.16  = 0.52, at closed discharge

w0d + wd + 2 /w2 / GP (w0 + w + 2 w2 + 2 w2 )

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Drag & pressure flow, cross-channel velocity V , = 1

V0

0.5

0.5

y
0.5
0.5

0.5

Cavity-lid driven flow (unwound channel)

0.5
0.5

0.5

perturbation solution (helical geometry)

At closed discharge with = 1, = 0.25,  = 0.5

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Drag & pressure flow, cross-channel velocity V , = 7

barrel

0.5

0.5
0.5
0.5

0.5
0.5

barrel

0.5

0.5

screw

screw

Visiovis design
= 0.16,  = 0.52
Large change in cross channel velocity for large aspect ratio.
Back pressure effects visible at closed discharge.

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Viscoelastic fluid flow

Differential viscoelastic model : Upper-Convected Maxwell
5

(1)

S + r S +2r d= 0
5

S=

S
+ S v S v t v S
t

(2)

First normal stress difference & constant shear viscosity

Developed in Frenet basis ( 1000 terms)
Zero order analytic solution available in pressure flow only
Expansion of each stress component in power of , 
At a given order, stress components are now explicit functions of known velocity gradients
Creates specific contribution to the flow :
Deborah number: De =

<w>0
D

w = . . . + De w + De2 w
= . . . + D e 
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Viscoelastic fluid, pressure flow, w

Curvature

pressure flow - Wp Newton - aspect 1

pressure flow - Wp Maxwell - aspect 1

0.5

2
1.5
1
0.5

0.4
0.3

= 1,  = 0.5

outer wall <---

0.1

0.1
0

-0.1

-0.1

-0.2

-0.2

-0.3

-0.3

-0.4

-0.4

--> inner wall

pressure flow - Wp Newton - aspect 1

0.3

outer wall <---

w0 + 2 w2 with De = 0

--> inner wall

0.5
0.4
0.3

0.2

0.2

0.1

0.1
y

-0.1

-0.1

-0.2

-0.2

-0.3

-0.3

-0.4

-0.4

-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall

outer wall <---

-0.5
0.1 0.2 0.3 0.4 0.5

2
1.5
1
0.5

0.4

pressure flow - Wp Maxwell - aspect 1

0.5

-0.5 -0.4 -0.3 -0.2 -0.1

-0.5 -0.4 -0.3 -0.2 -0.1

w0 + w + De2 wmxwl with  = 0.5, De = 1

= 1, = 0.25

-0.5
0.1 0.2 0.3 0.4 0.5

2
1.5
1
0.5

0.3
0.2

w0 + w with De = 0

Torsion

0.4

0.2

-0.5 -0.4 -0.3 -0.2 -0.1

0.5

2
1.5
1
0.5

-0.5 -0.4 -0.3 -0.2 -0.1

outer wall <---

-0.5
0.1 0.2 0.3 0.4 0.5
--> inner wall

w0 + 2 w2 + De w with = 0.25, De = 1

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Viscoelastic fluid, pressure flow, w

1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0.5

0.4

0.3

0.2

0.1

0 y

-0.1

--> inner wall

-0.5
0.1 0.2 0.3 0.4 0.5

-0.2

0
-0.3

-0.4

outer wall <---

-0.5 -0.4 -0.3 -0.2 -0.1

Curvature, w0 + w + De2 wmxwl with  = 0.5, De = 1, = 5

Large change in contours of w near the side walls
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0.5

0.4

0.3

0.2

0.1

0 y

-0.1

--> inner wall

-0.5
0.1 0.2 0.3 0.4 0.5

-0.2

0
-0.3

-0.4

outer wall <---

-0.5 -0.4 -0.3 -0.2 -0.1

Torsion, w0 + De w + 2 w2 with = 0.25, De = 2, = 5

Small twist in contours of w near the side walls
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Viscoelastic fluid, pressure flow, cross-channel velocity u, v

 = 0.5, Deborah De = 1
max

0.176

0.107

0.085

0.058

2 vortices appearing,
moving towards
the side walls
with higher aspect ratio

0.5

inner wall

max

v
<w>0

V  Maxwell

outer wall

aspect ratio

u
<w>0

0.5

V  Maxwell
0

inner wall

outer wall

0.5
0.5

0.5
0.5

0.5

0.5

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oyonnax 10/07/13

Viscoelastic fluid, pressure flow, w

2.5

w0 + (w + De2 wmxwl ), y = 0

w0 + w , y = 0
w pflw y = 0

w/ < w >0
2

1.5

w pflw y = 0.25
w0 + w , y = 0.25
w0 + (w + De2 wmxwl ), y = 0.25

0.5

0
0.5

0.4

0.3

0.2

0.1

0.1

0.2

0.3

x
0.4

0.5

 = 0.2, De = 0.73 : shift towards the outer wall validated by F.E. Calculations

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Conclusions
2D 1/2 viscous & viscoelastic fluids flow has been solved in a screw channel
constant pitch and depth, rectangular cross-section
with torsion and curvature taken into account
New model backed precisely by 3D F.E. calculations
Pressure flow is more sensitive to helical geometry than drag flow
In pressure flow, torsion of the helical channel puts the fluid in cross channel motion
Torsion effects are important for aspect ratio larger than one
Curvature effects diminish with large aspect ratios for Newtonian fluid ...
... but remain present for viscoelastic (UCM) fluid

Strong corrections to the PPM model are needed in view of finer

calculations of mixing efficiency and overall residence time
and screw design
[BMR+ 04] Y. Breaux, M. Moguedet, X. Raoul, JY. Charmeau, J. Balcaen, and D. Graebling. Series solutions for viscous
and viscoelastic fluids flow in the helical rectangular channel of an extruder screw. Journal of Non-Newtonian Fluid
Mechanics, 123(2-3):237257, 2004
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Plastication:
3D nonnewtonian

transient

synthesis and perspectives

nonisothermal

multiphasic

melting

stationnary (static vis, rotating barrel)

isothermal

fibre
breakage

2D 1/2 helicoidal

melt

viscoelastic

buckling
criterion

nonisothermal

temperature parameter

1D Flow Analysis Network

heat transfer

1D plastication extrusion and injection

Newtonian

velocity field
pathlines

nonNewtonian

screw characteristics

Visiovis

fibre breakage (solid/melt)

plastication profile

distribution longueur fibres

Barrel Windows
screw design

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References
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[BMR+ 04] Y. Breaux, M. Moguedet, X. Raoul, JY. Charmeau, J. Balcaen, and D. Graebling. Series
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extruder screw. Journal of Non-Newtonian Fluid Mechanics, 123(2-3):237257, 2004.
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K. P. Choo, N. R. Neelakantan, and J. F. T. Pittman. Experimental deep-channel velocity

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