This document summarizes an experiment on measuring the structural development of linear polyethylene fibers during melt-spinning. An apparatus was developed that can measure the fiber's tension, temperature, diameter, and x-ray diffraction patterns as a function of distance from the spinneret. Key factors that influence crystallinity and fiber morphology are rheological stretching of the melt and non-isothermal heat transfer effects. Results showed fiber diameter decreases, velocity increases, and crystallinity, orientation, and birefringence develop as the fiber moves down the spinline away from the spinneret. Higher take-up velocities resulted in thinner fibers and faster cooling rates.
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Structure Development During the Melt-spinning of Linear Polyethylene
This document summarizes an experiment on measuring the structural development of linear polyethylene fibers during melt-spinning. An apparatus was developed that can measure the fiber's tension, temperature, diameter, and x-ray diffraction patterns as a function of distance from the spinneret. Key factors that influence crystallinity and fiber morphology are rheological stretching of the melt and non-isothermal heat transfer effects. Results showed fiber diameter decreases, velocity increases, and crystallinity, orientation, and birefringence develop as the fiber moves down the spinline away from the spinneret. Higher take-up velocities resulted in thinner fibers and faster cooling rates.
This document summarizes an experiment on measuring the structural development of linear polyethylene fibers during melt-spinning. An apparatus was developed that can measure the fiber's tension, temperature, diameter, and x-ray diffraction patterns as a function of distance from the spinneret. Key factors that influence crystallinity and fiber morphology are rheological stretching of the melt and non-isothermal heat transfer effects. Results showed fiber diameter decreases, velocity increases, and crystallinity, orientation, and birefringence develop as the fiber moves down the spinline away from the spinneret. Higher take-up velocities resulted in thinner fibers and faster cooling rates.
Fibres Presented by V.Venkata Sai Kiran(2011TT10977) B.Manoj Kumar(2011TT10907) Experimental Synopsis Apparatus developed for studying the structural development during melt-spinning measures the following : Tension in the fibre/filament being extruded Fibre temperature Fibre diameter X-ray diffraction patterns These are measured as a function of the distance of monofilament from the spinneret. The above mentioned spinning variables play a key role in the crystallization kinetics and structure formation of synthetic fibres Equipment Equipment-components Screw Extruder-Metering Pump-Spinneret combo A melt spinning line has a rotating anode x-ray generator along with WAXD accessories. Feed roll whose velocity is established using a DC motor and speed controller and winder The spinning apparatus can be moved up/down.This allows us to obtain data as a function of spinneret distance. Crystallinity and fibre morphology during melt-spinning a polymer depend upon two factors : Rheological Factors (Stretching of melt) Non-isothermal effects (Heat transfer from filament) Birefringence trend : Birefringence values observed increased with spinline tension, velocity gradient during draw-down and the inverse of filament diameter. Discussions The maximum diameter shown is the diameter at die-swell region. From this point, the filament diameter decreases as the filament accelerates and reaches the take up velocity. The velocity is low in the die-swell region. It increases rapidly to take up velocity over a short distance. The velocity gradient first rapidly increases and then quickly decreases to zero as the take up velocity is reached. The peak in Velocity gradient profile becomes narrower with a decrease in mass flow rate. Or increasing the take up velocity at constant mass flow rate can thin down the filament being extruded. At higher speeds, higher cooling rates are achieved owing to smaller fibre diameters. Increase in maximum velocity gradient, increases the molecular orientation in the molten polymer. Crystallization begins at the peak of velocity gradient profile and this peak effects the kinetics of crystallization.
Temperature Profile As the fibre exits the spinneret, rapid cooling is seen until the crystallization begins. During crystallization, energy is released and this decreases the rate of cooling. This can be seen from a plateau like region in the temperature profile. X-ray peaks are seen for the first time just before the plateau-like region. Minimum diameter and maximum velocity of filament are attained at this stage(distance.) After the draw-down zone, cooling rates are higher because of higher surface area-volume ratio. As seen in the graph, plateau temperature decreases as the take- up velocity is increased(at a constant mass-flow rate). This is so because, increase in take up velocity, thins the filament down, facilitating the heat exchange with higher cooling rates.
Development of Crystallinity Crystallization begins when the velocity gradient reaches its peak and continues as the filament is taken-up by the bobbin. 60% crystallinity is attained at the onset of the temperature plateau and it increases down the spinline. This is because the filament temperature lies above Tg of the fibre. But, at very high spinning speeds, crystallization occurs at a relatively longer distance from the spinneret and due to high cooling rates, lower degrees of crystallinity are achieved. Birefringence Vs Spinline Tension Spinline Tension or stress increases either by increasing the take up velocity or by decreasing the mass flow rate, keeping the other process parameter constant. Birefringence increases steadily by increasing spinline tension. This is because of the stress induced crystallization in the fibre. Morphological Model