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Detachment of the Polymer Melt from the Roll Surface: Calendering Analysis and Data from a Shear Roll Extruder

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Published/Copyright: May 2, 2013
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International Polymer Processing
From the journal International Polymer Processing Volume 19 Issue 2

Abstract

The detachment behavior of a polymer melt from the hot roll surface/s during roll-driven processes affects the maximum production rates achievable in various processes including calendering, embossing and shear roll milling. Here the continuous shear roll milling process is used to investigate the conditions that lead to the detachment of the polymer melt from the surface of one or both heated rolls. During the shear roll milling process the polymer melt needs to continuously stick to one roll and periodically to stick and then to detach from the other roll (at the nip). Different roll speeds, surface roughness and temperatures are used to facilitate continuous stick to one roll and periodic stick and detachment from the other roll. Shear roll mill process fails to convey the melt in the forward direction under conditions for which the melt detaches from both rolls. The shear roll mill processing of a high density polyethylene revealed the detachment of the melt from both rolls under various combinations of operating parameters. A calendering model enabling the use of different roll diameters and roll velocities for incompressible generalized Newtonian fluids under isothermal and lubrication flow conditions was developed and used to understand the detachment dynamics. The detachment of the melt from both rolls was revealed to occur when the maximum shear stress at the roll surface exceeds the critical wall shear stress at which the onset of macroscopic wall slip is observed in simple shear flow. These findings suggest that the processing window for roll-driven processes is affected by the wall slip characteristics of the polymer melt and that the processing window can be widened using a better understanding of the wall slip behavior of the materials being processed.

∗ Mail address: D. M. Kalyon, Chemical, Biomedical and Materials Eng. Dept., Stevens Institute of Technology, Castle Point Station, Hoboken, NJ 07030 USA E-mail:

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Received: 2003-9-18
Accepted: 2004-2-10
Published Online: 2013-05-02
Published in Print: 2004-05-01

© 2004, Carl Hanser Verlag, Munich

Articles in the same Issue

  1. Contents
  2. Contents
  3. Editorial
  4. DuPont, IG Farbenindustrie, ICI and Japanese PA Fiber Manufacturers Polyamides 66 and 6
  5. Screw Extrusion
  6. Modeling the Flow in the Metering Zone of Single Screw Extruders Using a Helical Geometry Model
  7. Engineering Analysis of Devolatilization of Various Additives in Intermeshing Co-rotating Twin Screw Extruders
  8. Die Extrusion
  9. Novel Extrusion Dies with Rotating Rollers for CO2-Plastic Foam Production
  10. Experimental Investigation of the Development of Interfacial Instabilities in Two Layer Coextrusion Dies
  11. Detachment of the Polymer Melt from the Roll Surface: Calendering Analysis and Data from a Shear Roll Extruder
  12. Reactive Extrusion
  13. Reactive Extrusion of SAN/EPDM Blends
  14. Film
  15. Easy Tear Film of Biaxially Oriented PA 6/MXD 6 Blend by Double Bubble Tubular Film Process
  16. Deformation Behavior, Processability and Physical Properties for Biaxially Oriented Film of LLDPE
  17. Stretchability and Properties of LLDPE Blends for Biaxially Oriented Film
  18. Stretchability and Properties of Various LLDPE for Biaxially Oriented Film
  19. Molding
  20. Microinjection Molding with LIGA-Like Process
  21. Thermoforming
  22. On the Use of the Heating Stage to Control the Thickness Distribution in Thermoformed Parts
  23. PPS News
  24. PPS News
https://doi.org/10.3139/217.1822

Articles in the same Issue

  1. Contents
  2. Contents
  3. Editorial
  4. DuPont, IG Farbenindustrie, ICI and Japanese PA Fiber Manufacturers Polyamides 66 and 6
  5. Screw Extrusion
  6. Modeling the Flow in the Metering Zone of Single Screw Extruders Using a Helical Geometry Model
  7. Engineering Analysis of Devolatilization of Various Additives in Intermeshing Co-rotating Twin Screw Extruders
  8. Die Extrusion
  9. Novel Extrusion Dies with Rotating Rollers for CO2-Plastic Foam Production
  10. Experimental Investigation of the Development of Interfacial Instabilities in Two Layer Coextrusion Dies
  11. Detachment of the Polymer Melt from the Roll Surface: Calendering Analysis and Data from a Shear Roll Extruder
  12. Reactive Extrusion
  13. Reactive Extrusion of SAN/EPDM Blends
  14. Film
  15. Easy Tear Film of Biaxially Oriented PA 6/MXD 6 Blend by Double Bubble Tubular Film Process
  16. Deformation Behavior, Processability and Physical Properties for Biaxially Oriented Film of LLDPE
  17. Stretchability and Properties of LLDPE Blends for Biaxially Oriented Film
  18. Stretchability and Properties of Various LLDPE for Biaxially Oriented Film
  19. Molding
  20. Microinjection Molding with LIGA-Like Process
  21. Thermoforming
  22. On the Use of the Heating Stage to Control the Thickness Distribution in Thermoformed Parts
  23. PPS News
  24. PPS News
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