Viscoelastic simulation of film casting process for a polymer melt

Numerical simulations of the film casting process were performed using a finite element method for Newtonian and viscoelastic fluids. We simplified the governing equations by the assumption that the stress and velocity gradients in the thickness direction were negligible, and obtained the film thickness and mean value of stress and velocity components in the thickness direction as variables. Viscoelasticity was described by the Larson model with multiple relaxation, times. Non-isothermal conditions were considered by applying the time-temperature superposition law The simulation results for the several kinds of commercial low-density polyethylenes were compared to the experimental data for a laboratory-scale process at 190 degreesC and a commercial-scale process at 310 degreesC. The Mm width and Mm thickness distribution at chill roll, and the change of film width were in good agreement for the laboratory-scale process, but the agreement for the commercial-scale process was not as good. In the simulation of the commercial-scale process at high temperature, the value predicted by the use of the viscoelasticity for the original pellet showed poor agreement owing to the change of viscoelasticity in the process. The agreement was improved by the use of the viscoelasticity for the processed resin, which was changed from the original one. Next, viscoelastic effects on neck-in and edge bead phenomena were investigated. The neck-in and edge bead phenomena were considered to be affected by both the uniaxial elongational viscosity and planar elongational viscosity.