Extrudate swell and flow analysis of polystyrene melt flowing in an electro-magnetized die in a single screw extruder

An electro-magnetized capillary die via a parallel co-extrusion technique was used to study the changes in the overall and radial extrudate swell ratio of polystyrene (PS) melt flowing in a single screw extruder. The effects of magnetic flux density, wall shear rate (screw rotating speed) and die temperature were studied. The results suggested that, in the case of non-magnetic die the average overall swell ratio of the melt ranged from 1.25 to 1.55. The swelling ratio increased with increasing wall shear rate up to 8.5 sec(-1) and then decreased at 17.1 sec(-1). Increasing die temperature caused a reduction of extrudate swell ratio. The changes in extrudate swell ratio can be explained using the simultaneously measured velocity profiles during the flow in the die, and the swell ratio decreased with increasing radial position. Melt contraction of the melt layer near the die wall was observed. The die temperature was found to have no effect on the change of the radial extrudate swell profiles. When an electro-magnetized die was used, the average overall swell ratio was found to increase with increasing magnetic flux density to a maximum value and then decreased at higher flux densities. The magnetic flux density of the maximum swell was changed by the wall shear rate. It was associated with a balance of elastic and magnetic energies during the flow. The magnetic energy was thought to have a pronounced effect on the swell ratio at low shear rate and low die temperature. Considering the radial position, the highest swell ratio occurred at the duct center, in the range 2.4-3.3. There was no extrudate contraction of the melt layer near the die wall. Copyright (c) 2005 John Wiley & Sons, Ltd.