Who needs Rheology?

All those working on plastics

Rheology is a very pervasive science
whose data are extensively used
wherever plastics are used

‫ب؟‬١‫خ‬ٌٛٛ٠‫ اٌش‬ٌٝ‫حزبج إ‬٠ ِٓ

‫ه‬١‫ اٌجالعز‬ٍٝ‫ْ ػ‬ٍّٛ‫ؼ‬٠ ٓ٠‫ٌئه اٌز‬ٚ‫وً أ‬
‫ه‬١‫ّٕب رُ اعزخذاَ اٌجالعز‬٠‫اعغ أ‬ٚ ‫ ٔطبق‬ٍٝ‫بٔبرٗ ػ‬١‫خ رغزخذَ ث‬٠‫ ػٍُ ِٕزشش ٌٍغب‬ٟ٘ ‫ب‬١‫خ‬ٌٛٛ٠‫اٌش‬

The main parameters from capillary

‫‪rheological measurements:‬‬
‫‪MFR or MVR Shear Sensitivity‬‬
‫)‪Rheological curve (at different T‬‬
‫اٌّؼٍّبد اٌشئ‪١‬غ‪١‬خ ِٓ اٌم‪١‬بعبد اٌش‪ٌٛٛ٠‬خ‪١‬خ اٌشؼش‪٠‬خ‬
‫‪ MVR‬أ‪MFR ٚ‬‬
‫حغبع‪١‬خ اٌمصبر‪١‬خ‬
‫ِٕحٕ‪ ٝ‬اٌش‪ٌٛٛ٠‬خ‪١‬ب (ػٕذ دسخبد حشاسح ِخزٍفخ) االعزمشاس اٌحشاس‪ٞ‬‬
‫ِٕص‪ٙ‬ش اٌىثبفخ‬
‫لبٌت ِٕزفخ‬
‫ِمب‪ِٚ‬خ إٌّص‪ٙ‬ش‬
‫ِٕص‪ٙ‬ش اٌغحت‬
‫صٌخ اٌدذاس‬
 Thermal Stability

Melt Density
Die Swell
Melt Strength
Melt Drawdown
Wall Slip

The 4 areas where capillary rheometry is used

1. Quality Control
2. R&D Studies
‫‪3. Modelling of polymer processing‬‬
‫‪4. Polymer processing management‬‬

‫‪4‬‬

‫إٌّبطك األسثؼخ اٌز‪٠ ٟ‬غزخذَ ف‪ٙ١‬ب ل‪١‬بط اٌش‪ِٚ‬بر‪١‬ضَ اٌشؼش‪ٞ‬‬

‫ِشالجخ اٌد‪ٛ‬دح ‪1.‬‬
‫دساعبد اٌجحث ‪ٚ‬اٌزط‪٠ٛ‬ش ‪2.‬‬
‫ّٔزخخ ِؼبٌدخ اٌج‪ّ١ٌٛ‬ش ‪3.‬‬
‫إداسح ِؼبٌدخ اٌج‪ّ١ٌٛ‬شاد ‪4.‬‬
 1. Quality Control
Quality Control of incoming materials
Quality Control of finished products
Quality Control of intermediate products

‫مراقبت الجىدة‬

‫مراقبت جىدة المىاد الىاردة‬

 ‫مراقبت جىدة المىتجاث الىهائُت‬

‫مراقبت جىدة المىتجاث الىسُطت‬

Quality Control
It is the most common application of rheological measurements.
People usually evaluate MFR (or MVR). For this purpose a basic
manual MFR tester (extrusion plastometer) is adequate.
‫مرإقبة إلجودة‬
‫ر‬
‫إألكث شيوعا للقياسات إلريولوجية‬ ‫هذإ هو إلتطبيق‬

‫عادة ما يقوم إلناس بتقييم‬

MFR (‫ أو‬MVR).

‫يكف إختبار‬
‫ ي‬،‫لهذإ إلغرض‬
MFR

7
 ‫إألساس (مقياس إلبثق‬
‫ي‬ ‫إليدوي‬

‫يعرف عدد قليل جدإ من إلناس أنه يمكنهم توسيع نطاق إلتحكم عىل نطاق وإسع باستخدإم معدإت تدفق إلذوبان إألوتوماتيكية‬
‫‪:‬إلحديثة أو معدإت متعددة إلنقاط‪ .‬يمكنهم بسهولة إلحصول عىل معلومات ؤضافية من أجل‬

‫منصهر إلكثافة •‬

‫إالستقرإر إلحرإري •‬

‫حساسية إلقص •‬

‫تنتفخ إلقالب •‬

‫‪Very few people know that they can very broadly extend the‬‬ ‫‪control using a modern‬‬

‫‪•Shear Sensitivity‬‬
‫‪•Die Swell‬‬
automatic Melt Flow equipment or a multi-point equipment. They
can easily get additional information as for:
• Melt density
• Thermal Stability
A secondary but non-trivial consequence of using automatic
MFR equipment is that data can sistematically be stored
providing a consistent database of all incoming lots.
‫غث إلتافهة الستخدإم معدإت‬
‫تتمثل ؤحدى إلنتائج إلثانوية ولكن ر‬

MFR

‫إلتلقائية يف أنه يمكن تخزين إلبيانات بشكل بسيط مما يوفر قاعدة بيانات متسقة لجميع إلقطع إلوإردة‬

9
 ‫‪2. R&D Studies‬‬

‫‪Capillary Rheology plays a fundamental‬‬

‫‪role in many R&D projects.‬‬
‫درإسات إلبحث وإلتطوير ‪2.‬‬

‫يلعب علم إلريولوجيا إلشعرية دورإ أساسيا يف إلعديد من مشاري ع إلبحث وإلتطوير‬

‫إعتمادإ عىل ر‬
‫إلمشوع‪ ،‬يمكن إستخدإم جميع إلمعلمات إلريولوجية إلقابلة للقياس‬

‫‪Depending on the project, all measurable‬‬

‫‪rheological parameters may be used.‬‬

‫‪11‬‬
3. Modelling of polymer processing

Rheology provides the most important

set of data to feed simulation

12
‫‪programs.‬‬

‫‪Examples:‬‬
‫)‪Mould filling phase (Injection moulding‬‬
‫‪Molten plastic flow through an extrusion die‬‬

‫نمذجة معالجة إلبوليمر ‪3.‬‬

‫‪.‬يوفر علم إلريولوجيا أهم مجموعة من إلبيانات لتغذية برإمج إلمحاكاة‬
‫‪:‬أمثلة‬
‫مرحلة ملء إلقالب (صب إلحقن) تدفق إلبالستيك إلمنصهر من خالل قالب إلبثق‬

‫‪13‬‬
4. Polymer Processing management

Rheological measurements can be used to

control some process, such as extrusion.

14
 The control may be discontinous or continous (on-
line). In the latter case you may also apply an
automatic feedback to the production line.

4. ‫ّشاد‬١ٌٛ‫إداسح ِؼبٌدخ اٌج‬

‫ ِثً اٌجثك‬،‫بد‬١ٍّ‫ ثؼض اٌؼ‬ٟ‫خ ٌٍزحىُ ف‬١‫خ‬ٌٛٛ٠‫بعبد اٌش‬١‫ّىٓ اعزخذاَ اٌم‬٠.
‫ خظ اإلٔزبج‬ٍٝ‫خ ػ‬١‫ك ِالحظبد رٍمبئ‬١‫ضب رطج‬٠‫ّىٕه أ‬٠ ،‫شح‬١‫ اٌحبٌخ األخ‬ٟ‫ ف‬.)‫ اٌخظ‬ٍٝ‫ ِغزّشح (ػ‬ٚ‫طشح عٍغخ أ‬١‫ْ اٌغ‬ٛ‫لذ رى‬
Another example:

15
Severity of processing conditions can be checked by
comparing MFR before and after moulding.
An increase of MFR up to 10-15 % is usually
considered safe; higher percentages indicate poor
stability of the material. Sometimes this can be
reduced by modifying the processing conditions.
Otherwise the material may be not adequate.
A manual MFR is enough for materials whose flow is
not very fast.

‫ِثبي آخش‬:
16
 ‫‪ّ٠‬ىٓ اٌزحمك ِٓ شذح ظش‪ٚ‬ف اٌّؼبٌدخ ػٓ طش‪٠‬ك ِمبسٔخ‬
‫‪MFR‬‬
‫‪.‬لجً ‪ٚ‬ثؼذ اٌزشى‪ً١‬‬
‫ػبدح ِب رؼزجش ص‪٠‬بدح ِؼذي اٌزشش‪١‬ح اٌىج‪١‬ج‪ ٟ‬ثٕغجخ رصً إٌ‪ ٪01-01 ٝ‬إِٓخ؛ ‪ٚ‬رش‪١‬ش‬
‫إٌغت اٌّئ‪٠ٛ‬خ األػٍ‪ ٝ‬إٌ‪ ٝ‬ضؼف اعزمشاس اٌّبدح‪ .‬ف‪ ٟ‬ثؼض األح‪١‬بْ ‪ّ٠‬ىٓ رمٍ‪ً١‬‬
‫‪.‬رٌه ػٓ طش‪٠‬ك رؼذ‪ ً٠‬شش‪ٚ‬ط اٌّؼبٌدخ‪ٚ .‬إال فمذ ال رى‪ ْٛ‬اٌّبدح وبف‪١‬خ‬
‫‪٠‬ىف‪ٟ‬‬
‫‪MFR‬‬
‫‪.‬اٌ‪١‬ذ‪ٌٍّٛ ٞٚ‬اد اٌز‪ ٟ‬ال ‪٠‬ى‪ ْٛ‬رذفم‪ٙ‬ب عش‪٠‬ؼب خذا‬

‫‪Compounding‬‬

‫‪17‬‬
 Academic + Extrusion
Industrial R&D Injection
Raw Polymers moulding
Producers RHEOLOGY Textiles
Film Blow
Rotational Moulding
moulding Calendering
Recycling

18
Now, let’s look at the specific
technologies
Here we shall review each of
them, showing what’s necessary
to satisfy their basic needs.

‫ دعىوا ولقٍ وظرة علً التقىُاث المحذدة‬،‫اِن‬

19
 ‫‪.‬سىراجع هىا كل واحذ مىهم‪ ،‬مىضحُه ما هى ضرورٌ لتلبُت احتُاجاتهم األساسُت‬

‫‪EXTRUSION‬‬

‫‪By this technique we produce continous items such as‬‬

‫‪sheets, pipes, cables, profiles‬‬
‫‪Examples:‬‬
‫‪• Sheets for glazing, sheets to be thermoformed (bags,‬‬
‫اٌجثك ‪ -‬اٌجثك‬
‫ِٓ خالي ٘زٖ اٌزمٕ‪١‬خ‪ٕٔ ،‬زح ػٕبصش ِغزّشح ِثً األ‪ٚ‬ساق ‪ٚ‬األٔبث‪١‬ت ‪ٚ‬اٌىبثالد ‪ٚ‬اٌّالِح‬
‫‪:‬أِثٍخ‬
‫)صفبئح ٌٍزضخ‪١‬ح‪ ،‬صفبئح ِشاد رشى‪ٍٙ١‬ب حشاس‪٠‬ب (أو‪١‬بط‪ ،‬حب‪٠ٚ‬بد طؼبَ •‬
‫أٔبث‪١‬ت ٌٍغ‪ٛ‬ائً ‪ٚ‬اٌغبصاد ‪ٚ‬إٌفب‪٠‬بد •‬
‫اٌىبثالد اٌى‪ٙ‬شثبئ‪١‬خ •‬

‫‪20‬‬
 • ‫افز‬ٌٕٛ‫ِالِح ا‬ٚ ‫افز‬ٌٕٛ‫غ ا‬٠‫ف ٌزذس‬٠‫ٍِفبد رؼش‬

food containers)
•Pipes for liquids, gases, wastes
•Electrical cables
•Profiles for windows shieldings, windows profiles

21
Extrusion plant

23
24
Slit distributor die (to
manufacture film or sheets)

Coathanger die

A spider die (to

manufacture
rigid/tubular films)25
 How can rheology help in Extrusion?
1. Providing data for Quality Control of incoming
materials (virgin/recycled)

26
Low level control
MFR
Shear Sensitivity MFR
High level control
as above + Capillary
Rheological curve rheometer
Thermal Stability MFR Ancillaries:
Die Swell Die Swell, Melt
Strength, SW
Melt Strength, Drawdown
Wall Slip
‫ اٌجثك؟‬ٟ‫ب ف‬١‫خ‬ٌٛٛ٠‫غبػذ ػٍُ اٌش‬٠ ْ‫ّىٓ أ‬٠ ‫ف‬١‫و‬
1. ‫ش٘ب‬٠ٚ‫ ِؼبد رذ‬/ ‫خ‬١ٌٚ‫اسدح أ‬ٌٛ‫اد ا‬ٌّٛ‫دح ا‬ٛ‫بٔبد ٌّشالجخ خ‬١‫ش اٌج‬١‫ف‬ٛ‫)ر‬
ٜٛ‫رحىُ ِٕخفض اٌّغز‬
27
 MFR
‫خ اٌمص‬١‫حغبع‬
MFR
ٜٛ‫ اٌّغز‬ٌٟ‫اٌزحىُ ػب‬
ٖ‫اسد أػال‬ٌٛ‫ ا‬ٛ‫ إٌح‬ٍٝ‫ ػ‬+
‫ب‬١‫خ‬ٌٛٛ٠‫ اٌش‬ٕٝ‫ِٕح‬
ٞ‫االعزمشاس اٌحشاس‬
‫لبٌت رٕزفخ‬
‫ اٌغحت‬،‫ح‬ٛ‫ش اٌم‬ٙ‫ِٕص‬
‫صٌخ اٌدذاس‬
How can rheology help in Extrusion?

2. Providing basic data for

• Designing extrusion screws
• Designing extrusion dies

28
 • Optimizing process management

What’s necessary:
Capillary
•The rheological curve
rheometer
•Info on elastic effects (sharkskin,
orange peel, melt fracture…)

‫ اٌجثك؟‬ٟ‫ب ف‬١‫خ‬ٌٛٛ٠‫ّىٓ أْ رغبػذ اٌش‬٠ ‫ف‬١‫و‬

2. ٓ‫خ ػ‬١‫بٔبد األعبع‬١‫ش اٌج‬١‫ف‬ٛ‫ر‬
• ‫ش اٌجثك‬١ِ‫ُ ِغب‬١ّ‫رص‬
• ‫اٌت اٌجثك‬ٛ‫ُ ل‬١ّ‫رص‬
• ‫بد‬١ٍّ‫ٓ إداسح اٌؼ‬١‫رحغ‬
ٞ‫س‬ٚ‫ ضش‬ٛ٘ ‫ِب‬:
• ٟ‫بث‬١‫ االٔغ‬ٕٝ‫إٌّح‬
ٞ‫بة اٌشؼش‬١‫بط االٔغ‬١‫ِم‬
• ‫ش‬ٙ‫ وغش إٌّص‬، ‫ لشش اٌجشرمبي‬، ‫شاد اٌّشٔخ (خٍذ اٌمشػ‬١‫ِبد ػٓ اٌزأث‬ٍٛ‫ِؼ‬...)

29
 How can rheology help in Extrusion? 3.
Getting basic information to manage co-extrusion

30
(this technology is even more spreading since internal layers are
often made of recycled material)
Coextrusion is optimised when different layers show similar
viscosity (at the shear rates estimated near the joining region)
when layers meet togheter.
What’s necessary: Capillary
The rheological curve rheometer

‫ اٌجثك؟‬ٟ‫ب ف‬١‫خ‬ٌٛٛ٠‫ّىٓ أْ رغبػذ اٌش‬٠ ‫ف‬١‫و‬

3. ‫خ إلداسح اٌجثك اٌّشزشن‬١‫ِبد األعبع‬ٍٛ‫ اٌّؼ‬ٍٝ‫ي ػ‬ٛ‫اٌحص‬
31
 (‫ش٘ب‬٠ٚ‫اد ِؼبد رذ‬ِٛ ِٓ ‫ػخ‬ٕٛ‫ْ ِص‬ٛ‫خ غبٌجًب ِب رى‬١ٍ‫أزشبسا ألْ اٌطجمبد اٌذاخ‬
ً ‫خ أوثش‬١ٕ‫)٘زٖ اٌزم‬
‫ب‬ٙ‫ اٌطجمبد ِغ ثؼض‬ٟ‫خخ ِّبثٍخ (ثّؼذالد اٌمص اٌّمذسح ثبٌمشة ِٓ ِٕطمخ االٔضّبَ) ػٕذِب رٍزم‬ٚ‫ش اٌطجمبد اٌّخزٍفخ ٌض‬ٙ‫ٓ اٌجثك اٌّشزشن ػٕذِب رُظ‬١‫زُ رحغ‬٠.
ٟ‫بث‬١‫ االٔغ‬ٕٝ‫ إٌّح‬:ٞ‫س‬ٚ‫ ضش‬ٛ٘ ‫ِب‬
INJECTION MOULDING

By this technique we get an infinite number of items

for everyday life, such as
• Casing for PC, printers, fax, phones …

•Car components (bumpers, heaters grills and ducts,

trims, headlamps,..)
•Motorcycle helmets
•Toys (Lego, …)

32
 ‫صب إلحقن•‬
‫من خالل هذه إلتقنية ‪ ،‬نحصل عىل عدد ال حرص له من إلعنارص للحياة إليومية ‪ ،‬مثل •‬
‫إلشخص وإلطابعات وإلفاكس وإلهوإتف • •‬
‫ي‬ ‫‪ ...‬غالف للكمبيوتر‬

‫)‪..‬مكونات إلسيارة (مصدإت ‪ ،‬سخانات ‪ ،‬مجاري إلهوإء ‪ ،‬إلديكورإت ‪ ،‬إلمصابيح إألمامية ‪• • ،‬‬
‫)‪...‬خوذإت إلدرإجات إلنارية • إأللعاب (ليغو ‪• • ،‬‬
‫‪• 22‬‬
‫هيكل آلة إلتشكيل بالحقن •‬

‫‪33‬‬
The structure of an injection moulding machine

34
The toggle and clamp units

The plasticizing unit (the

extruder) with the screw
position after feeding

35
The
injection
moulding
process

36
37
38
 ‫?‪How can rheology help in Injection Moulding‬‬
‫‪1. Providing data for Quality Control of incoming‬‬
‫)‪materials (virgin/recycled‬‬
‫كيف يمكن أن يساعد علم إلريولوجيا يف قولبة إلحقن؟‬
‫)توفث إلبيانات لمرإقبة جودة إلموإد إلوإردة (أوليه ‪ /‬معاد تدويرها ‪1.‬‬
‫ر‬
‫تحكم منخفض إلمستوى‬
‫‪MFR‬‬
‫حساسية إلقص‬
‫عال إلمستوى‬ ‫تحكم ي‬
‫عىل إلنحو إلوإرد أعاله ‪+‬‬

‫‪39‬‬
 ‫ريولوج إالستقرإر إلحرإري‬
‫ي‬ ‫منحن‬
Low level control
MFR
MFR
Shear Sensitivity
High level control
as above +
Capillary
Rheological curve MFR rheometer
Thermal Stability

40
 ‫‪How can rheology help in‬‬ ‫‪Injection‬‬
‫?‪Moulding‬‬

‫‪2. Providing basic data for‬‬

‫•‬ ‫‪Designing moulds‬‬
‫و‪١‬ف ‪ّ٠‬ىٓ أْ ‪٠‬غبػذ ػٍُ اٌش‪ٌٛٛ٠‬خ‪١‬ب ف‪ ٟ‬ل‪ٌٛ‬جخ اٌحمٓ؟‬
‫ر‪ٛ‬ف‪١‬ش اٌج‪١‬بٔبد األعبع‪١‬خ ي ‪2.‬‬
‫رصّ‪ ُ١‬اٌم‪ٛ‬اٌت •‬
‫رحغ‪ ٓ١‬إداسح اٌؼٍّ‪١‬بد •‬
‫ِب ٘‪ ٛ‬ضش‪ٚ‬س‪ :ٞ‬إٌّحٕ‪ ٝ‬اٌش‪ٌٛٛ٠‬خ‪ٟ‬‬
‫ِم‪١‬بط اٌضغظ اٌشؼش‪ٞ‬‬
‫سثّب ‪٠‬ى‪٘ ْٛ‬زا ٘‪ ٛ‬أُ٘ رطج‪١‬ك ٌٍش‪ٌٛٛ٠‬خ‪١‬ب ف‪ِ ٟ‬ؼبٌدخ اٌجالعز‪١‬ه‬
 ‫اٌت‬ٛ‫بٔبد اإلدخبي ٌّحبوبح ًِء اٌم‬١‫ث‬
• Optimizing process management

What’s necessary: Capillary

rheometer
The rheological curve

THIS IS PERHAPS THE MOST IMPORTANT APPLICATION OF

RHEOLOGY IN PLASTICS PROCESSING:
INPUT DATA FOR MOULD FILLING SIMULATION

42
43
How can rheology help in Injection Moulding?

3. Getting basic information to manage coinjection

(this technology allows moulding, for instance, of
two or more coloured component in a unique
piece, e.g., car tail-lamps, PC keys)
Co-injection is analyzed by the same programs for
mould filling.

What’s necessary:
The rheological curves of Capillary
different materials rheometer

‫ٌجخ اٌحمٓ؟‬ٛ‫ ل‬ٟ‫ب ف‬١‫خ‬ٌٛٛ٠‫غبػذ ػٍُ اٌش‬٠ ْ‫ّىٓ أ‬٠ ‫ف‬١‫و‬

3. ‫خ إلداسح اٌحمٓ اٌّشزشن‬١‫ِبد األعبع‬ٍٛ‫ اٌّؼ‬ٍٝ‫ي ػ‬ٛ‫اٌحص‬

44
‫رغّح ٘زٖ اٌزمٕ‪١‬خ ثصت‪ ،‬ػٍ‪ ٝ‬عج‪ ً١‬اٌّثبي‪ِ ،‬ى‪ ٓ١ٍِٔٛ ٓ١ٔٛ‬أ‪ ٚ‬أوثش ف‪ ٟ‬لطؼخ فش‪٠‬ذح ِٓ ٔ‪ٛ‬ػ‪ٙ‬ب‪ ،‬ػٍ‪ ٝ‬عج‪ ً١‬اٌّثبي‪ِ ،‬صبث‪١‬ح ر‪ ً٠‬اٌغ‪١‬بسح ‪ِٚ‬فبر‪١‬ح اٌىّج‪ٛ١‬رش (‬
‫)اٌشخص‪ٟ‬‬
‫‪٠.‬زُ رحٍ‪ ً١‬اٌحمٓ اٌّشزشن ِٓ خالي ٔفظ اٌجشاِح ًٌّء اٌم‪ٛ‬اٌت‬
‫‪ِ:‬ب ٘‪ ٛ‬ضش‪ٚ‬س‪ٞ‬‬
‫إٌّحٕ‪١‬بد اٌش‪ٌٛٛ٠‬خ‪١‬خ ٌٍّ‪ٛ‬اد اٌّخزٍفخ‬
‫ِم‪١‬بط اٌضغظ اٌشؼش‪ٞ‬‬

‫‪45‬‬
46
Injection
moulding
(co-injection)

47
 FILM FORMING TECHNOLOGY

By this technique we manufacture plastic films to be

found everywhere, such as
• Greenhouses protection films
• Shoppers

48
‫‪•Food packaging‬‬

‫‪There are two basic technologies:‬‬

‫‪•Blown film‬‬
‫‪•Cast film‬‬

‫رىٕ‪ٌٛٛ‬خ‪١‬ب رشى‪ ً١‬األغش‪١‬خ‬

‫ِٓ خالي ٘زٖ اٌزمٕ‪١‬خ‪ٔ ،‬م‪ َٛ‬ثزصٕ‪١‬غ أفالَ ثالعز‪١‬ى‪١‬خ ‪ّ٠‬ىٓ اٌؼث‪ٛ‬س ػٍ‪ٙ١‬ب ف‪ ٟ‬وً ِىبْ‪ِ ،‬ثً‬
‫غشبء حّب‪٠‬خ اٌذف‪١‬ئبد اٌضساػ‪١‬خ • اٌّزغ‪ٛ‬ل‪• ْٛ‬‬
‫رغٍ‪١‬ف اٌّ‪ٛ‬اد اٌغزائ‪١‬خ •‬
‫• ‪ٕ٘:‬بن رمٕ‪١‬زبْ أعبع‪١‬زبْ‬
‫غشبء ٔفخ‬
‫غشبء اٌصت •‬

‫‪49‬‬
Blown film process

50
The Cast Film Process

51
How can rheology help in Film forming Technology?
1. Providing data for Quality Control of
incoming materials (virgin/recycled)

52
Low level control
MFR
MFR
Shear Sensitivity

High level control

as above +
Thermal Stability MFR
Rheological curve
Die Swell Capillary
rheometer
Melt Strength, Drawdown

‫كُف َمكه أن َساعذ علم الرَىلىجُا فٍ تكىىلىجُا تشكُل األغشُت؟‬

1. ‫ معاد تذوَرها‬/ ‫)تىفُر البُاواث لمراقبت جىدة المىاد الىاردة (أولُت‬

53
 ‫تحكم مىخفض المستىي‬

‫‪MFR‬‬

‫حساسُت القصاتُت‬

‫تحكم عالٍ المستىي‬

‫علً الىحى الىارد أعالي‬ ‫‪+‬‬

‫مىحىً الرَىلىجُا لالستقرار الحرارٌ‬

‫قالب مىتفخ‬

‫مقاومت المىصهر‪ ،‬السحب‬

‫‪54‬‬
How can rheology help in Film forming technology?

2. Providing basic data for

• Designing extrusion screws
• Designing extrusion dies
• Optimizing process management

What’s necessary: Capillary

rheometer
The rheological curve

‫ً األفالَ؟‬١‫ب رشى‬١‫خ‬ٌٕٛٛ‫ رى‬ٟ‫ب ف‬١‫خ‬ٌٛٛ٠‫غبػذ ػٍُ اٌش‬٠ ْ‫ّىٓ أ‬٠ ‫ف‬١‫و‬

55
 3. َ‫خ إلداسح اٌجثك اٌّشزشن ٌألفال‬١‫ِبد األعبع‬ٍٛ‫ اٌّؼ‬ٍٝ‫ي ػ‬ٛ‫اٌحص‬
(‫ ػشش طجمبد‬ٌٝ‫صً إ‬٠ ‫ ثثك ِب‬ٟ‫َ ٔشبسن ف‬ٛ١ٌ‫ ٘زٖ حبخخ ِبعخ ألٕٔب ا‬،‫ب‬ٙ‫ ث‬ٌٝ‫ب األفالَ اٌّذ‬١‫خ‬ٌٕٛٛ‫ رى‬ٟ‫)!ف‬
‫خخ ِّبثٍخ (ثّؼذالد اٌمص اٌّمذسح ثبٌمشة ِٓ ِٕطمخ االٔضّبَ) ػٕذِب‬ٚ‫ش اٌطجمبد اٌّخزٍفخ ٌض‬ٙ‫ٓ اٌجثك اٌّشزشن ػٕذِب رظ‬١‫زُ رحغ‬٠

‫ة‬ٛ‫ اٌطجمبد ثبٌثم‬ٟ‫رٍزم‬ .

ٟ‫خ‬ٌٛٛ٠‫ اٌش‬ٕٝ‫ إٌّح‬:ٞ‫س‬ٚ‫ ضش‬ٛ٘ ‫ِب‬

How can rheology help in Film forming technology?

3. Getting basic information to manage film
coextrusion
(in cast film technology this is a critical need since
today we co-extrude up to ten layers!)
Coextrusion is optimised when different layers

56
 show similar viscosity (at the shear rates

What’s necessary: Capillary

The rheological curve rheometer

estimated near the joining region) when layers

meet togheter.
BLOW MOULDING

By this technology we manufacture hollow items, such as:

• Water bottles (typically made of PET)

‫ضشثخ صت‬.
57
 ‫ِٓ خالي ٘زٖ اٌزىٕ‪ٌٛٛ‬خ‪١‬ب‪ٔ ،‬م‪ َٛ‬ثزصٕ‪١‬غ اٌؼٕبصش اٌّد‪ٛ‬فخ‪ِ ،‬ثً‪ • :‬صخبخبد اٌّ‪١‬بٖ (اٌّصٕ‪ٛ‬ػخ ػبدح ِٓ‬
‫)‪PET‬‬
‫)‪ ...‬حب‪٠ٚ‬بد ٌٍؼذ‪٠‬ذ ِٓ اٌغ‪ٛ‬ائً (اٌّشش‪ٚ‬ثبد ‪ِٚ‬غزحضشاد اٌزدّ‪ٚ ً١‬اٌّ‪ٛ‬اد اٌى‪١ّ١‬بئ‪١‬خ •‬

‫‪•Containers for many liquids (beverages, cosmetics,‬‬

‫)…‪chemicals‬‬

‫‪58‬‬
Items
obtained
by
Blow
Moulding
Actually, today’s blow technology has developed
towards the manufacturing of big size items (not
necessarily hollow), such as:
• Bags
• Bathtubes

• Car gasoline tanks

There are two basic blow moulding technologies:

•Extrusion –blow
•Injection -blow

60
‫‪:‬ف‪ ٟ‬اٌ‪ٛ‬الغ‪ ،‬رط‪ٛ‬سد رمٕ‪١‬خ اٌضشثخ اٌ‪ٔ َٛ١‬ح‪ ٛ‬رصٕ‪١‬غ ػٕبصش وج‪١‬شح اٌحدُ (‪١ٌٚ‬ظ ثبٌضش‪ٚ‬سح ِد‪ٛ‬فخ)‪ِ ،‬ثً‬
‫حمبئت •‬
‫أٔبث‪١‬ت اٌحّبَ •‬
‫خضأبد ثٕض‪ ٓ٠‬اٌغ‪١‬بساد •‬
‫‪ٕ٘:‬بن ٔ‪ٛ‬ػبْ ِٓ رمٕ‪١‬بد صت إٌفخ األعبع‪١‬خ‬
‫اٌجثك ‪ -‬إٌفخ •‬
‫اٌحمٓ ‪ -‬إٌفخ •‬
‫⬇ اٌصفحخ اٌز‪ ٟ‬رٍ‪ٙ١‬ب‬
‫ضشثخ اٌجثك ٘‪ ٟ‬ػٍّ‪١‬خ ثثك رٍ‪ٙ١‬ب اٌضشثخ‬

‫‪61‬‬
Extrusion-blow is an
extrusion process
followed by the blow

62
Extrusion-blow requires a polymer
with
•a high molecular weight
•a broad molecular weight
distribution

The reason:
The vertical molten ‘parison’ must stand for
some time before being inflated

63
 ‫ّشا ِغ‬١ٌٛ‫زطٍت ضشثخ اٌجثك ث‬٠

• ‫ ِشرفغ‬ٟ‫ئ‬٠‫صْ خض‬ٚ
• ٟ‫ئ‬٠‫صْ اٌدض‬ٌٍٛ ‫اعغ‬ٚ ‫غ‬٠‫ص‬ٛ‫ر‬
‫اٌغجت‬ :
ّٗ١‫لذ لجً رضخ‬ٌٛ‫ ٌجؼض ا‬ٞ‫د‬ّٛ‫ش اٌؼ‬ٙ‫ظ" إٌّص‬٠‫مف "اٌجبس‬٠ ْ‫دت أ‬٠

How can rheology help in Extrusion -

BlowTechnology?
1. Providing data for Quality Control of
incoming materials

64
Low level control
MFR
MFR
Shear Sensitivity

High level control

as above +
Thermal Stability Capillary
rheometer
Rheological curve (η0)
Die Swell MFR Ancillaries:
Die Swell, Melt
Melt Strength, Drawdown Strength, SW

65
How can rheology help in Extrusion - Blow technology?

2. Providing basic data for

• Designing extrusion dies

• Optimizing process management
Capillary
What’s necessary: rheometer
The rheological curve MFR Ancillaries:
Melt Strength Die Swell, Melt
Strength, SW
• Designing extrusion screws
 Injection-blow is an
injection process
followed by the blow.

First, by injection we
produce pre-forms..
…then we inflate
them
 Injection-blow requires polymers with
• a low molecular weight
• (a narrow molecular weight distribution)

Low molecular weight is required to ease

injection
(A narrow molecular weight distribution helps
to get high mechanical properties)

49
 ‫يتطلب حقن رصبة بوليمرإت مع‬
‫•‬ ‫جزين منخفض •‬
‫ي‬ ‫وزن‬
‫•‬ ‫إلجزين( •‬
‫ي‬ ‫)توزي ع ضيق للوزن‬
‫•‬ ‫جزين منخفض لتخفيف إلحقن‬
‫ي‬ ‫مطلوب وزن‬
‫•‬ ‫إلجزين إلضيق يف إلحصول عىل خصائص ميكانيكية عالية(‬
‫ي‬ ‫)يساعد توزي ع إلوزن‬

‫‪How can rheology help in Injection -‬‬

‫?‪BlowTechnology‬‬
‫‪1. Providing data for Quality Control of‬‬
‫‪incoming materials‬‬
 Low level control
MFR
MFR
Shear Sensitivity

High level control

MFR
as above +
Thermal Stability
Capillary
Rheological curve rheometer

How can rheology help in Injection - Blow technology?

2. Providing basic data for

• Designing extrusion screws
• Designing extrusion dies
• Modelling the blow stage
• Optimizing process management

What’s necessary: Capillary

rheometer
The rheological curve
MFR Ancillaries:
Melt Strength
Melt Strength, SW
 ROTATIONAL MOULDING
In this technology, a mould, containing the plastics as
fine powder, is rotating in an oven along two
orthogonal axis.
The plastics melts and distributes along the internal
surface of the mould.
‫صب إلتناوب‬.
ٓ٠‫س‬ٛ‫ي ِح‬ٛ‫ ط‬ٍٝ‫ فشْ ػ‬ٟ‫ ف‬،ُ‫ق ٔبػ‬ٛ‫ه وّغح‬١‫ اٌجالعز‬ٍٝ‫ ػ‬ٞٛ‫حز‬٠ ٞ‫ اٌز‬،‫س اٌمبٌت‬ٚ‫ذ‬٠ ،‫ب‬١‫خ‬ٌٕٛٛ‫ ٘زٖ اٌزى‬ٟ‫ف‬
ٓ٠‫ِزؼبِذ‬.
‫ ٌٍمبٌت‬ٍٟ‫ي اٌغطح اٌذاخ‬ٛ‫ ط‬ٍٝ‫صع ػ‬ٛ٠ٚ ‫ه‬١‫ة اٌجالعز‬ٚ‫ز‬٠.
‫ٌؼت أطفبي‬ٚ ‫خ‬١‫ى‬١‫ ِثً • وشاد ثالعز‬،‫فخ‬ٛ‫ ػٕبصش ِد‬ٍٝ‫ب ٔحصً ػ‬١‫خ‬ٌٕٛٛ‫ِٓ خالي ٘زٖ اٌزى‬
• ‫كبثة إلحجم‬
‫حاويات ر‬

74
By this technology we get hollow items, such as
•Plastics balls, toys
•Big size containers
Rotational
moulding

76
Since there is no pressure, the plastic must be very
fluid in order to be able to flow under its own weight.
Accordingly, to master this technology you must
know the viscosity at very low shear rate, i.e., the so-
called ‘zero-shear viscosity’. This can be calculated
by a Capillary rheometer.
ٗٔ‫ص‬ٚ ‫زّىٓ ِٓ اٌزذفك رحذ‬٠ ٝ‫ه عبئال خذا حز‬١‫ْ اٌجالعز‬ٛ‫ى‬٠ ْ‫دت أ‬٠ ،‫د ضغظ‬ٛ‫خ‬ٚ َ‫ٔظشا ٌؼذ‬.
‫خخ اٌمص‬ٚ‫ "ٌض‬ّٝ‫غ‬٠ ‫ ِب‬ٞ‫ أ‬،‫خخ ثّؼذي لص ِٕخفض خذا‬ٚ‫دت أْ رؼشف اٌٍض‬٠ ،‫ب‬١‫خ‬ٌٕٛٛ‫ إلرمبْ ٘زٖ اٌزى‬،‫فمب ٌزٌه‬ٚ
ٞ‫بط اٌضغظ اٌشؼش‬١‫اعطخ ِم‬ٛ‫ّىٓ حغبة رٌه ث‬٠ ."ٞ‫اٌصفش‬.
ُ‫ز‬٠ٚ )‫ أوثش‬ٚ‫مخ أ‬١‫ دل‬01 ‫ٍخ (غبٌجب‬٠ٛ‫سح رغزّش ٌفزشح ط‬ٚ‫ ألْ اٌذ‬ٞ‫ش االعزمشاس اٌحشاس‬٠‫ضب رمذ‬٠‫ش ٌال٘زّبَ أ‬١‫ْ ِٓ اٌّث‬ٛ‫ى‬٠ ‫لذ‬
‫ ضغظ‬ٞ‫ْ أ‬ٚ‫ اٌزذفك د‬ٟ‫ دسخخ اٌحشاسح ِشرفؼخ لذس اإلِىبْ (ِٓ أخً اٌّغبػذح ف‬ٍٝ‫)اٌحفبظ ػ‬.
It may be also interesting to estimate the Thermal
Stability since the cycle lasts quite a long time (often 20
min or more) and the temperature is kept as high as
possible (in order to help the flow under no pressure).

How can rheology help in Rotational Moulding?

Providing data for Quality Control of

78
incoming materials

Low level control

MFR MFR

High level control

as above +
Thermal Stability MFR
Rheological curve
Capillary
rheometer
55
 COMPOUNDING

Polymers are very seldom processed as produced.

Very often they are modified by incorporation of other

substances (additives, fillers, reinforcements,
pigments), which are added for a number of reasons:

80
•To help processing (processing aids)

•To help maintaining properties during product lifetime

•To specialise the polymer to specific needs (material

tailoring)

Sometimes these operations are done by the raw

polymer producers:
• finishing or compounding

Sometimes they are done by indipendent companies:

• compounding

In any case, the modification is done by extrusion

Compounding is becoming increasingly

important because of recycling of plastics, which
requires not only blending with virgin material,
but also a specific tailoring of the formulations.

82
How can rheology help in Compounding ?
Providing data for Quality Control of

84
incoming / outcoming materials

Low level control

MFR
MFR
Shear Sensitivity

High level control

as above +
Thermal Stability MFR
Rheological curve
Capillary
rheometer

85
A special category of compounders:
Masterbatches producers
Masterbatches are concentrates of one or more additive to a virgin
polymers; they are added to the plastics to give them the
expected properties.
For instance:
Colour masterbatches
Flame resistant masterbatches
Masterbatches are obtained by mixing the additives to a very low
molecular weight polymer (often PS or PE)
Their use is very widespread because it makes compounding
easier or free from environmental problems.
86
How can rheology help Masterbatches producers ?

Providing data for Quality Control of

87
 incoming / outcoming materials

Low level control

MFR MFR
Shear Sensitivity

Generally speaking, low level control is adequate

It may interesting to note that before the appearance of

automatic MFR, the evaluation of MFR itself was not
feasible (because of exceedingly high values of MFR:
usually higher than 50 g/10 min)

88
 PLASTICS RECYCLING

Plastics Recycling is becoming more and more

an issue.

The main goal is to reuse all materials and

related waste in a manner similar to nature,
which means to reintroduce material into a
cycle.

89
The various processes of Plastics Recycling
91
92
For compounding of recycled materials the
Quality Control of incoming plastics is
particularly critical due
• to the broad variety of materials to be found
around, and

•their unknown history

A high level control is strongly advisable!

(even if often refused by the operators)

93
For compounding of recycled materials the Quality
Control of outcoming plastics is also particularly
critical due to the high number of processing
operations undergone by the material to be sold
(3, 4, 5… ?)

Again, a high level control is strongly

advisable!
(even if often refused by the operators)

94
How can rheology help Plastics Recycling operators ?
Providing data for Quality Control of
incoming / outcoming materials

MFR
MFR
Shear Sensitivity
Themal Stability

95
 Conclusions:

•Capillary Rheology really has a very

broad range of applications !

•The potential has not be fully exploited,

however…

96
 Compounding
Academic + Extrusion
Industrial R&D Injection
Raw Polymers moulding
Producers RHEOLOGY
Textiles
Film Blow
Rotational Moulding
moulding Calendering
Recycling

97