Effect of some injection molding processing conditions on weld lines characteristics

The influence of injection and mold temperature as well as holding time on the knit-line characteristics in samples of Nylon 6 obtained by injection molding was analysed. The characteristics of the surface defect seem to be governed by the shrinkage rate and amount in the weld line zone.

Modeling the interactions between light and crystallizing polymer during fast cooling

In this work, an experimental set-up able to quench thin polymer films whilst recording the sample thermal history as well as the overall and depolarized light intensities of a laser beam emerging from the sample is described. The interactions between the light beam and the crystallizing material have been modeled accounting for absorption and scattering phenomena. The proposed model was found to be able to reproduce the ex- perimentally observed behavior of light intensities and it was validated by comparison with conventional DSC analysis. On the basis of this model, a method to obtain crystallinity evo- lution is proposed and applied to some fast cooling runs. The method was applied to q…

LARGE DEFORMATION CREEP BEHAVIOR OF A SOLID POLYMER.

Abstract The effect of loading rate and strain on the creep behavior after sample yielding has been studied in previous communications (14–15) for Mylar in tension and for Lexan in compression. In this work the creep behavior of Lexan samples previously elongated is considered both in tension and in compression. A procedure which collects all the data independently of both loading rate and initial creep strain is proposed.

EFFECT OF DRAWING ON THE STRUCTURE AND THE DYNAMIC-MECHANICAL BEHAVIOR OF SALTED POLYCAPROAMIDE.

Abstract Structural determinations, obtained through density, birefringence, and WAXS measurements, are reported for nylon 6/inorganic salt fiber samples as a function of draw ratio. They confirm the possibility of achieving very high amorphous orientation in these systems. Dynamic-mechanical data have also been collected which allow determination of glass transition temperatures. These are also discussed in terms of structural parameters.

The anisotropic behaviour of a preoriented poly (ethylene terephthalate) during plastic deformations

Data on the anisotropic tensile behavior of samples cut along several directions of a biaxially oriented PET sheet are here presented. Shear deformations were observed together with the usual elongations. The data are compared with the predictions of a non-linear model recently proposed.

Model analysis of uniaxial and biaxial stretching of polymer melts

The biaxial extension results byDenson et al. are compared with the predictions of a model of non-linear viscoelasticity. Date of uniaxial extension on the same material (a commercial polyisobutylene) are taken for extending the comparison. The model used seems to adequately describe both types of elongational flow with the same value of the single adjustable parameter.

The viscoelastic behavior of nylon 6/lithium halides mixtures

Stress-relaxation experiments in the limit of small deformations have been carried out in a wide range of temperatures for pure nylon 6 and its mixtures with LiBr and/or LiCl. Master curves have been constructed, by allowing horizontal shifts only, showing the shape typical for semicrystalline polymers in the case of pure nylon and that of essentially amorphous polymers in the case of salted samples. The glass transition temperatures determined from the plot logaT− 1/T is increased when in the presence of salts. All such effects are considered to reflect the binding action of Li+ and Br− ions.

Experimental study of stress-relaxation behaviour of polycarbonate after yielding

The viscoelastic behaviour of a bisphenol A polycarbonate after yielding is described by means of empirical superposition of coordinates along both time and stress axis, which allow collecting stress relaxation data, taken both in tension and in compression, into a master curve.

The non-isothermal rheological behaviour of molten polymers: Shear and elongational stress growth of polyisobutylene under heating

Data of stress growth under both shear and elongational kinematics have been taken in presence of heating temperature ramps on a commerical polyisobutylene.

Crystallization kinetics in relation to polymer processing

Phase distribution of quenched samples has been determined by a deconvolution procedure of WAXS spectra in a wide range of cooling rates. The informations collected together with isothermal and DSC results provide a very wide set of data on the crystallization kinetics of polymers relevant which covers conditions encountered in most polymer processing operations. They have been compared with predictions of a non-isothermal crystallization model assuming two independent and parallel crystallization processes competing during solidification.

Non-Isothermal Effects in the Elongational Flow of Polymer Melts

Non-isothermal histories occur in almost all polymer processing, and however only a few experimental and theoretical studies have been devoted to the rheological response of the polymeric fluids under non-isothermal conditions. A systematic study, which cannot however be considered exhaustive, has been recently carried out in this field by Bogue and coworkers1–3.

Influence of processing conditions on some properties of anionically synthesized polycaprolactam in presence of lithium chloride

Nylon 6–LiCl systems of various concentrations were prepared by anionic polymerization of caprolactam in the presence of salt. A depression of both crystallization rate and melting temperature was evidenced through x-ray, density, and DSC analyses. Such a preliminary characterization allowed for choosing the proper conditions in order to obtain amorphous fibers from a spinning operation which was performed at a temperature lower than the pure polymer melting point. These results are of technological relevance, especially in view of obtaining, as in similar cases, large amorphous orientations through a spinning–drawing process and high-modulus fibers after subsequent crystallization. Also, t…

On the packing–holding flow in the injection molding of thermoplastic polymers

Injection molding tests were performed on a Ny66 resin. Data of mass entering the mold during the packing–holding stage as a function of filling flow rate and holding time are presented. The experimental results are discussed on the basis of a simple model of the packing–holding stage. Only a small part of density increase due to crystallization seams to be compensated by the packing–holding extra flow.

Analysis of the packing stage in injection molding of thermoplastic polymers

Injection molding tests were performed on a Ny 66 resin. Data are presented on the mass entering the mold during the packing-holding stage as a function of filling flow rate and holding time. The experimental results are discussed on the basis of a simple model of the packing-holding stage. Only a small part of the density increase due to crystallization seems to be compensated by extra flow during the packing-holding stage.

Surface Anisotropy in the Expansion Behavior of Laminated Quasi-Isotropic Composites

Mesure a l'aide d'un extensometre des deformations thermiques superficielles de deux materiaux stratifies resine epoxy-fibre de graphite. Les resultats dependent de la direction de mesure, l'anisotropie superficielle associee est inversement proportionnelle aux dimensions de l'echantillon et proportionnelle au rapport d'anisotropie d'une lamelle isolee. Comparaison avec la theorie des stratifications

Dilute solution rheology of flexible macromolecules (bead–rod model)

The rheological behavior of dilute solutions of flexible macromolecules is studied by means of a freely jointed multiple bead–rod model. The solution of the equations describing the mechanics of the system is obtained by means of a numerical procedure, which applies to arbitrary flow conditions. The case of the transient stress in uniaxial elongational flow is developed in some detail. A comparison with bead–spring models shows both quantitative and qualitative differences which are briefly discussed.

Capillary experiments of flow induced crystallization of HDPE

Flow-induced crystallization experiments are made in a capillary apparatus modified with a downstream reservoir under pressure. Capillary length, diameter, and entrance angle are changed, as well as flow rate. The results show that the crystallization temperature is influenced both by the elongational flow at the capillary entrance and by the shear flow along the capillary. The independent effect of the pressure equals that obtained under static conditions. The effect of shear is correlated in terms of shearing work.

Polymer Solidification under Pressure and High Cooling Rates

Abstract Polymer solidification under processing conditions is a complex phenomenon in which the kinetics of flow, high thermal gradients and high pressures determine the product morphology. The study of polymer structure formed under pressure has been mainly made using conventional techniques such as dilatometry and differential scanning calorimetry under isothermal conditions or non isothermal conditions but at cooling rates several orders of magnitude lower than those experienced in industrial processes. A new equipment has been recently developed and improved to study the crystallization of polypropylene when subjected to pressure and cooled rapidly. An experimental apparatus essentiall…

ESTIMATION OF INJECTION PRESSURE DURING MOLD FILLING.

Dimensionless diagrams for estimating the bulk temperature of the flow front and injection pressure in the limit of small viscous generation are obtained. Also, a criterion for neglecting viscous generation is identified, The diagrams, based on the Lord and Williams model, refer to rectangular geometry and amorphous materials. A satisfactory comparison is obtained with literature data taken on polystyrene. A reasonable estimate of polyethylene injection pressure was obtained by roughly accounting for latent heat of crystallization through modified thermal diffusivity.

Ultimate tensile properties and dart impact behaviour of coextruded films of LDPE and LLDPE were compared with those of films made from blends of the same resins. The effect of composition and of both blow up ratio and axial draw ratio of the blowing process on film properties was explored. The results indicate that, at least for semicompatible systems like that considered here, films made from blends and coextruded ones have mechanical properties very close to each other. Die Festigkeitseigenschaf ten und das Verhalten beim Kugelfalltest von coextrudiertcn Filmen aus LDPE und LLDPE wurden mit den entsprechenden Eigenschaften von aus Mischungen dieser Polymere hergestellten Filmen vergliche…

Effect of annealing below the glass transition on the loss peak of glassy polycarbonate

Physical behavior and morphology of biaxially rolled low-density polyethyleneX

Abstract Biaxial rolling was carried out on low-density polyethylene, and the rolled samples were studied using various techniques. Scanning electron microscopy and analysis of transport properties were used to obtain structural information, which was correlated to thermomechanical and dynamic-mechanical behavior. Results indicate that the initial morphology is destroyed by rolling and that clumps of molecules, like fibrils, are generated parallel to the rolling plane. The molecular orientation in the plane is mainly radial, with some reinforcement, particularly at high rolling degree, along axes diagonal with respect to the rolling directions. The rolling drastically reduces the molecular …

The recovery after bending of polycarbonate sheets

The recovery after bending has been extensively studied for metal sheets. The data presented in this work show that in the case of polymeric materials viscoelastic effects play a very important role. In particular the influence of deformation rate, the time the sample is held under load and the recovery time is analysed. A master curve is obtained by proper modification of a recent analysis developed for metal sheets.

Elongational flow of dilute polymer solutions

In this work, elongational viscosity data obtained for dilute solutions of Separan NP 20 in glycerol, are presented. The data are taken under transient stress conditions with two different experimental techniques.

Testing of a constitutive equation with free volume dependent relaxation spectrum

A model of non-linear viscoelasticity with relaxation times dependent upon free volume is here proposed. The free volume is related to the isotropic part of the stress tensor by means of a simple differential equation. The model predictions are compared with a large amount of experimental results taken on polymeric melts or concentrated solutions and reported in the literature. The single parameter of the model is determined, within each set of data, by fitting of the viscosity curve. A satisfactory agreement is obtained with data taken under both elongation and shear for which also the relaxation behavior after single and double strain steps is considered.

Testing of a constitutive equation for entangled networks by elongational and shear data of polymer melts

An entangled network such as a polymer melt or a concentrated solution is here described by a set of two simultaneous equations. One of them is a balance of entanglements, the other gives the stress in the classical form of aMaxwell equation.

Master curves of viscoelastic behavior in the plastic region of a solid polymer

Stress relaxation and creep tests following strain ramps were made on Mylar, both above and below the yield stress. The ramp velocity was varied over a 40-fold range. All data exhibit nonlinear viscoelastic behavior. However, those obtained above the yield point, i.e., in the plastic region, could be reduced to single master curves for both the creep and the relaxation tests by means of a simple time shift factor. This factor is inversely proportional to the strain rate existing just prior to the test.

Compression creep and stress-relaxation tests have been performed on PMMA at several deformations after the sample yielding. At large loading rates, the behaviour observed was found significantly affected by the temperature rise due to the plastic deformation. Creep and stress-relaxation data taken holding the samples at constant temperature after the material loading could be collected into single curves by means of a time shift factor proportional to the loading rate. Retardations- und Relaxationsuntersuchungen bei Druckbeanspruchung von PMMA wurden bei verschiedenen Deformationen oberhalb des Fliespunktes durchgefuhrt. Bei hohen Beanspruchungsgeschwindigkeiten wurde festgestellt, das das…

Effect of cooling rate on the viscoelastic properties in the plastic zone of solid polymers

PMMA and PC samples were subjected to several cooling rates from the glass transition temperature.

EFFECT OF MOISTURE ON THE BULK PROPERTIES OF SALTED POLY(CAPROAMIDE).

The glass-transition temperature (Tg) and the elastic modulus of nylon-6 and its mixtures with 4% w/w LiCl and with 2% LiCl+3% LiBr were investigated. In one set of experiments care was taken to avoid absorption of moisture during the measurements. In another set of experiments, samples were exposed to atmospheric humidity for different lengths of time. Both unoriented and oriented specimens were investigated. The presence of 4% LiCl almost doubles the amount of moisture absorbed at equilibrium by nylon-6. The Tg was found to be greatly affected by the moisture content and by salt type. When strict precautions to exclude moisture are taken, the addition of 4% LiCl raises the Tg of nylon-6 b…

Morphology and transport parameters of cold-rolled low-density polyethylene

Abstract Sheets of low-density polyethylene were rolled at room temperature. Samples with two different degrees of rolling were obtained. The structural changes induced by the rolling treatments were investigated using scanning electron microscopy and by analyzing the transport properties. Results suggest that in the analyzed range of deformation, the rolling induces a domain structure as a consequence of a nonhomogeneous distribution of the deformation. At lower local deformation the initial morphology is still present, while at higher deformation clumps of folded chains oriented along the rolling directions are observable. The transport properties indicate that the rolling treatment reduc…

Compressive recovery behaviour of a polycarbonate

Abstract Polycarbonate samples were subjected to large compression strains (beyond yielding) and were unloaded after some degree of stress relaxation. The subsequent deformation recovery was measured for several values of strain, loading rate and duration of stress relaxation. All the data could be reported as a single curve by normalizing the recovered strain with the stress at the end of the relaxation period.

A simplified description of viscoelastic behavior of polymers as illustrated with biaxially-oriented poly(ethylene terephthalate)

A rheological model of solid polymers is proposed. Its mechanical analog is a parallel of a linear spring and a Maxwell element with variable viscosity. The viscosity of the dashpot is allowed to change with stress both directly, by an Eyring-type mechanism, and through free volume changes according to the Doolittle equation. Predictions of the model reproduce many of the features shown, especially after yielding, by constant velocity stress-strain, stress-relaxation and creep data taken at room temperature on biaxially-oriented poly(ethylene terephthalate) over a wide range of loading rates.

Sul Miglioramento della Processabilità del Nanocomposito a base di Polistirene Sindiotattico e Argille Modificate

Sul Miglioramento della Processabilità del Nanocomposito a base di Polistirene Sindiotattico e Argille Modificate

Heat of crystallization significantly slows down polymer cooling and thus pressure drop increase during mould filling with thermoplastic crystalline polymers. If a correction of thermal diffusivity can account for such a cooling slow down at least as far as the effect on pressure drop is concerned, the use of nonisothermal crystallization kinetics may be avoided in the simulation of mould filling. A procedure to identify such a correction is outlined in this work. Pressure drop values during cavity filling calculated by using a corrected thermal diffusivity in the model proposed by Lord and Williams favourably compare with literature data taken with polypropylene and polyethylene resins. Be…

The stress relaxation behaviour after compression yielding of two semicrystalline polymers, a low density polyethylene and an isotactic polypropylene, is investigated. Data taken at several strains, reached with different sample loading rates, are considered. Master curves are obtained by means of dimensionless stress and time measures, similar to those recently adopted for some amorphous polymers. Die Spannungsrelaxation nach Druckbeanspruchung wurde an zwei semikristallinen Polymeren, Polyethylen neidriger Dichte und isotaktischem Polypropylen, untersucht. Die bei unterschiedlichen Deformationen, welche mit unterschiedlichen Beanspruchungsgeschwindigkeiten erreicht wurdern, erhaltenen Erg…

Crystallization of polymer melts under fast cooling. II. High-purity iPP

SYNOPSIS Samples of a high-purity isotactic polypropylene (iPP) were quenched from the melt so as to monitor cooling history. A continuous variation of morphology and crystal structure was obtained with cooling rate. This is discussed in relation to sample thermal history evidencing that cooling history relevant to quenched samples is in the neighborhood of 90°C. In particular the samples are essentially mesomorphic when at this temperature cooling rates larger than 80°C/s were adopted, while below a few tens of °C/s only a­ monocline form is obtained. Densities of quenched samples were compared with predictions of an isokinetic extrapolation of Avrami model of polymer crystallization kinet…

Crystallization Behaviour at High Cooling Rates of Two Polypropylenes

Phase distribution of quenched samples of two isotactic polypropylenes, having different molecular weight distributions, was evaluated by a deconvolution procedure of WAXD spectra. The dependence on cooling rate of the two resins shows the low molecular weights rich polymer is characterized by a faster kinetics with an α-monoclinic to mesomorphic transition taking place at higher cooling rates.

Analysis of gate freeze-off time in injection molding

Gate solidification time is an important topic in injection molding technology, as it determines cycle time, which itself is an important issue in the economics of the production process. In this work, a study of the effect of both gate and cavity geometries on gate solidification time was conducted, using a commercial polymer, injection molded with constant holding pressure into a rectangular cavity. Three cavity lengths were used, and for each, two cavity thicknesses were adopted. Spe- cial dies containing different gates were assembled in the mold. Gate thickness was found to be the most important factor determining gate sealing time. However, the cavity geometry is also quite important.…

Stress relaxation of a polyisobutylene under large strains

Stress relaxation data after single and double elongational strain “steps” were collected on a commercial polyisobutylene, Oppanol B 50. Analogously to other cases a separability of deformation and time effects was observed over an extended time region for the relaxation after single “steps”. Moreover, by comparing the results after double with those after single steps, it was noted that any rheological equation of integral type having a rigorously constant memory function is not able to describe accurately the full body of results presented here. On the other hand the data were favorably compared with the predictions of a model proposed earlier.