Rheological modeling of fracture in plug‐assisted vacuum thermoforming

The fracture of polymeric sheets is one of the practical problems occurring during plug‐assisted vacuum thermoforming. This defect can occur during both the plug‐assist and vacuum‐forming stages. This article focuses on two issues: (1) the origins of fracture creation and (2) the determination of the process parameters needed for removal of the defect. The results of our work not only lead to an understanding of the cause of this problem but also enable us to calculate the parameters that affect the fracture of polymeric sheets during plug‐assisted vacuum thermoforming. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Dynamic characteristics of plug‐assist thermoforming process

Plug‐assist thermoforming is a well‐known technique in polymer processing because of its interesting features. The dynamic value of driving‐force for the stretching process is determined based on equilibrium equation. This amount of force is required for applying to a plug to stretch a sheet. It is used for calculation of the required theoretical work and power of a plug‐assist thermoforming process. By using a nonlinear viscoelastic rheological model in the proposed mathematical model, its validity was examined by performing experimental tests on ABS sheets. POLYM. ENG. SCI., 2009. © 2008 Society of Plastics Engineers     

Structure and properties of new thermoforming bionanocomposites based on chitin whisker‐graft‐polycaprolactone

Thermoformable bionanocomposites of chitin whisker‐graft‐polycaprolactone (CHW‐g‐PCL) were synthesized by initiating the ring‐opening polymerization of caprolactone monomer onto the CHW surface under microwave radiation. In this case, the “graft from” strategy contributed to long and dense “plasticizing” PCL tails onto the CHW surface as the key of thermoforming, and, therefore, such bionanocomposites were injection‐molded as the sheets with a structure of cocontinuous phase mediated with the entanglement of grafted PCL chains. The structure and properties of the molded CHW‐g‐PCL sheets were investigated by FTIR, XRD, SEM, DSC, DMTA, contact angle measurement, and tensile test. With an increase of the PCL content in CHW‐g‐PCL, the strength and elongation as well as the hydrophobicity of the nanocomposites increased at one time. This is the first report on the thermoformable polymer‐grafted nanocrystal derived from natural polysaccharide. Moreover, such new bionanocomposites with good mechanical performances could have great potential applications. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

The role of process parameters in determining wall thickness distribution in plug‐assisted thermoforming

This article describes the results of a comprehensive investigation to determine the link between process parameters and observed wall thickness output for the plug‐assisted thermoforming process. The overall objective of the work was to systematically investigate the process parameters that may be adjusted during production to control the wall thickness distribution of parts manufactured by plug‐assisted thermoforming. The parameters investigated were the sheet temperature, plug temperature, plug speed, plug displacement, plug shape, and air pressure. As well as quantifying the effects of each parameter on the wall thickness distribution, a further aim of the work was to improve the understanding of the physical mechanisms of deformation of the sheet during the different stages of the process. The process parameters shown to have the greatest effect on experimentally determined wall thickness distribution were the plug displacement, sheet temperature, plug temperature, and plug shape. It is proposed that during the plug‐assisted thermoforming of polystyrene the temperature dependent friction between the plug and sheet surface was the most important factor in determining product wall thickness distribution, whereas heat transfer was shown to play a less important role. POLYM. ENG. SCI., 50:1923–1934, 2010. © 2010 Society of Plastics Engineers     

Rheological properties of polymer-added lubricating oils

Rheological measurements of polyisobutylene solutions are presented. A mineral oil of low viscosity has been used as solvent. The combined effects of concentration, molecular weight and temperature were studied. It is found that the rheological data, when plotted as N₁λ_E/(η-η_s) versus λ_Eγ fall on a master curve over several decades of the dimensionless shear rate, irrespective of temperature, polymer concentration and molecular weight. The findings of this work can be used to address the problem of hydrodynamic lubrication of a journal bearing using a viscoelastic lubricant.     

An integrated qualitative and quantitative modeling framework for computer‐assisted HAZOP studies

The article proposes a novel practical framework for computer‐assisted hazard and operability (HAZOP) that integrates qualitative reasoning about system function with quantitative dynamic simulation in order to facilitate detailed specific HAZOP analysis. The practical framework is demonstrated and validated on a case study concerning a three‐phase separation process. The multilevel flow modeling (MFM) methodology is used to represent the plant goals and functions. First, means‐end analysis is used to identify and formulate the intention of the process design in terms of components, functions, objectives, and goals on different abstraction levels. Based on this abstraction, qualitative functional models are constructed for the process. Next MFM‐specified causal rules are extended with systems specific features to enable proper reasoning. Finally, systematic HAZOP analysis is performed to identify safety critical operations, its causes and consequences. The outcome is a qualitative hazard analysis of selected process deviations from normal operations and their consequences as input to a traditional HAZOP table. The list of unacceptable high risk deviations identified by the qualitative HAZOP analysis is used as input for rigorous analysis and evaluation by the quantitative analysis part of the framework. To this end, dynamic first‐principles modeling is used to simulate the system behavior and thereby complement the results of the qualitative analysis part. The practical framework for computer‐assisted HAZOP studies introduced in this article allows the HAZOP team to devote more attention to high consequence hazards. © 2014 American Institute of Chemical Engineers AIChE J 60: 4150–4173, 2014     

Three‐dimensional color prediction modeling of single‐ and double‐layered woven fabrics

In this research, the three‐dimensional structural and colorimetric modeling of three‐dimensional woven fabrics was conducted for accurate color predictions. One‐hundred forty single‐ and double‐layered woven samples in a wide range of colors were produced. With the consideration of their three‐dimensional structural parameters, three‐dimensional color prediction models, K/S‐, R‐, and L*a*b*‐based models, were developed through the optimization of previous two‐dimensional models which have been reported to be the three most accurate models for single‐layered woven structures. The accuracy of the new three‐dimensional models was evaluated by calculating the color differences ΔL*, ΔC*, Δh°, and ΔE_CMC(2:1) between the measured and the predicted colors of the samples, and then the error values were compared to those of the two‐dimensional models. As a result, there has been an overall improvement in color predictions of all models with a decrease in ΔE_CMC(2:1) from 10.30 to 5.25 units on average after the three‐dimensional modeling.     

Rheological and thermal properties of binary blends of polypropylene and poly(ethylene‐CO‐1‐octene)

Dynamic viscoelastic properties of binary blends consisting of an isotactic polypropylene (i‐PP) and ethylene‐1‐octene copolymer (PEE) were investigated to reveal the relation between miscibility in the molten state and the morphology in the solid state. In this study, PEE with 24 wt % of 1‐octene was employed. The PEE/PP blend with high PEE contents showed two separate glass‐relaxation processes associated with those of the pure components. These findings indicate that the blend presents a two‐phase morphology in the solid state as well as in the molten state. The PEE/PP blend with low PEE content showed a single glass‐relaxation process, indicating that PEE molecules were probably incorporated in the amorphous region of i‐PP in the solid state. The DMTA analysis showed that the blends with low PEE contents presented only one dispersion peak, indicating a certain degree of miscibility between the components of these blends. These results are in accordance with the results of the rheological analysis. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 1634–1639, 2001     

Optimization of single‐zone drying of polymer solution coatings using mathematical modeling

Optimal conditions for drying polymer–solvent coatings result from a trade‐off between minimizing the residual solvent level and creating defects. This article describes an application of automated constrained optimization with a detailed mathematical drying model to find the optimal drying conditions for a prototypical coating in a single‐zone oven. The optimization process seeks oven conditions that minimize the residual solvent level for a fixed oven residence time without boiling the solvent within the coating. The optimal oven conditions include the air temperature and coating‐side and substrate‐side heat‐transfer coefficients. The conditions are constrained to physically reasonable values. According to our results, the optimal coating‐side heat‐transfer coefficient is always equal to or greater than the optimal substrate‐side heat‐transfer coefficient. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 78: 149–165, 2000     

Rheological modeling and finite element simulation of epoxy adhesive creep in FRP-strengthened RC beams

We have shown that a significant creep occurs at the concrete–fiber reinforced polymer (FRP) interface based on double shear long-term test. The primary test parameters were the shear stress to ultimate shear strength ratio, the epoxy curing time before loading as well as the epoxy thickness. The test results showed that when the epoxy curing time before loading was earlier than seven days the shear stress level significantly affected the long-term behavior of epoxy at the interfaces, and in particular the combined effect of high shear stress and thick epoxy adhesive can result in interfacial failure if subjected to high-sustained stresses. In this paper, based on the previous experimental observations, an improved rheological model was developed to simulate the long-term behavior of epoxy adhesive at the concrete–FRP interfaces. Furthermore, the newly developed rheological creep model was incorporated in finite element (FE) modeling of a reinforced concrete (RC) beam strengthened with FRP sheets. The use of rheological model in FE setting provides the opportunity to conduct a parametric investigation on the behavior of RC beams strengthened with FRP. It is demonstrated that creep of epoxy at the concrete–FRP interfaces increases the beam deflection. It is also shown that consideration of creep of epoxy is essential if part or the entire load supported by FRP is to be sustained.     

Rheological properties of poly(ethylene glycol)/poly(N‐isopropylacrylamide‐co‐2‐acrylamido‐2‐methylpropanesulphonic acid) semi‐interpenetrating networks

For the increasing demands of multifunctional materials in applications such as drug delivery system, a pH‐ and temperature‐responsive polyelectrolyte copolymer gel system was studied using rheometry. Rheological properties, determined by plate–plate rheometry in oscillatory shear, of hydrogels formed by free radical initiated copolymerization of N‐isopropylacrylamide (NIPA) and 2‐acrylamido‐2‐methylpropanesulphonic acid (AMPS) in the presence of methylene bisacrylamide (MBAA) as crosslinker are compared with the properties of semi‐interpenetrating network (SIPN) polyelectrolyte gels made by incorporation of poly(ethylene glycol) with molar mass 6000 g mol^?1 (PEG6000). Based on our systematic studies for this PEG/SIPN system, the effects of initiator and crosslinker concentration, relative proportions of comonomer units in the main chains, PEG6000 content and temperature on viscoelastic properties, unusual high storage moduli at small strain for the SIPN were discussed. The SIPN gel with characteristics of PEG molecules as well as pH and temperature responsiveness from AMPS and NIPA units has potential application in drug delivery system design. Ice‐like rheological behavior of the PEG/AMPS‐NIPA SIPN gels at low temperature was first time reported and water remains homogeneous without phase separation in PEG/AMPS‐NIPA SIPN hydrogels at low temperature may be considered as an ideal candidate for water storage material. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Rheology and microstructure of functionalized polymer‐modified asphalt

Viscoelastic and morphological properties of functionalized‐polymer‐modified asphalt, FPMA, have been described as function of number of epoxy groups presented in the functionalized polymer. At low temperatures, simple viscoelastic models can predict the elastic response of FPMA at short times and its viscous behavior at long times. The increase of epoxy groups yielded an increase on activation energy for viscous deformation of FPMA, and so, on its resistance to irreversible deformations under strain cycles. From ambient to higher temperatures, emulsion model can predict rheological properties of FPMA because they behave as viscoelastic emulsions. Modification of relaxation spectrum for FPMA due to the presence of a polymer network was not as strong as in normal PMA, thus, the rheological behavior of FPMA was found similar to systems having weak networks. However, the network became stronger as the number of epoxy groups was increased. This trend was verified by morphology of FPMA. Emulsion‐like structure was observed for all FPMA but differentiating each other by the polymer particle size. It was also observed that increase on epoxy groups, polymer particle size in the FPMA decreased, and higher stability at 180°C of FPMA was observed. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Rheological and thermal behaviour of poly(N‐isopropylacrylamide)/alginate smart polymeric networks

Interpenetrating polymeric networks based on sodium alginate and poly(N‐isopropylacrylamide) (PNIPAAm) covalently crosslinked with N,N′‐methylenebisacrylamide have been investigated using rheology, thermogravimetry, differential scanning calorimetry, X‐ray diffraction measurements and scanning electron microscopy (SEM). An improved elastic response of the samples with a higher PNIPAAm content and increased amount of crosslinking agent was found. The temperature‐responsive behaviour of the hydrogel samples was evidenced by viscoelastic measurements performed at various temperatures. It is shown that the properties of these gels can be tuned according to composition, amount of crosslinking agent and temperature changes. X‐ray scattering analysis revealed that the hydrophobic groups are locally segregated even in the swollen state whilst cryo‐SEM showed the highly heterogeneous nature of the gels. Copyright © 2011 Society of Chemical Industry     

Rheological aspects of fiber spinning from cellulose solutions in N‐methylmorpholine‐N‐oxide

Based on rheological experiments with a cellulose solution in N‐methylmorpholine‐N‐oxide (NMMO), it was found that the shearing stress generated in the flowing viscoelastic fluid decreases with an l/d ratio in a rheometer capillary. This reduces the elastic response and the outflow of the fluid becomes more uniform. At constant temperature, the elongational viscosity of the solidified stream of the cellulose solution in NMMO is reduced with increase of the deformation rate, which makes it possible to increase the fiber‐formation velocity within the air zone. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 79: 1860–1868, 2001     

Rheological behavior and microstructure of aqueous suspension of carboxylated core‐shell structured latex particle

Core‐shell type carboxylated particles form a flocculated structure in aqueous suspension with neutralization of carboxyl groups. Rheological behaviors of the suspension have been studied at various temperatures, and microstructures of the suspension have been discussed from the rheological behaviors and SAXS measurements. At 25°C, G′ is larger than G″ in all ω regions, and G′ is almost independent of ω, and the diffraction peak is detected by SAXS. These results mean that a three‐dimensional network of interconnected lattice‐like flocculated structure is formed. With increasing temperature, ω dependency of G′ becomes stronger and distance of the particles of the structure does not changed. These mean the network linkage is disrupted partially by thermal motion, and the interconnected lattice‐like flocculated structure changes to an isolated lattice‐like one with increasing temperature. With increasing the degree of neutralization, an isolated structure changes to an interconnected three‐dimensional structure decreasing the thermal motion just like decreasing temperature. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 1627–1633, 2001     

Application of residence time distribution technique to the study of the hydrodynamic behaviour of a full‐scale wastewater treatment plant plug‐flow bioreactor

The hydrodynamic behaviour of a full‐scale wastewater treatment plant (WWTP) bioreactor treating municipal wastewater, situated in Granollers (Barcelona, Spain), has been studied by means of a residence time distribution (RTD) technique using lithium (chloride) as tracer. The bioreactor studied is designed to work as a plug‐flow reactor and it is divided into two independent lanes (1 and 2), each one composed of four compartments in series resulting in a total volume of 3970 m³ per lane. During the RTD experiments, working flow was 1000 m³ h^?1 per lane, which implied an ideal mean residence time of 3.97 h. When a lithium chloride tracer was injected in the bioreactor, both lanes showed a similar highly non‐ideal hydrodynamic behaviour, which had an important effect on the reactor's performance. This global RTD was complemented by means of local RTDs in different locations of the bioreactor in order to determine qualitatively the reactor's mixing regime. Different non‐ideal models (namely axial dispersion, tanks‐in‐series and some simple compartment models) have been tested for the modelling of the experimental RTD. The best model fitting RTD data for Lanes 1 and 2 was a configuration consisting of four mixed tanks in series. The RTD study proposed in this work will permit improvement of the reactor's mixing performance, which is of special interest in future projects including simultaneous removal of carbon, nitrogen and phosphorus. Copyright © 2005 Society of Chemical Industry     

Rheological kinetics of acrylonitrile/amino ethyl‐2‐methyl propenoate copolymer solutions in dimethyl sulfoxide

Viscosity behavior of dimethyl sulfoxide solutions of acrylonitrile (AN)/amino ethyl‐2‐methyl propenoate (AEMP) copolymer was discussed. Rheological kinetics of the solutions was studied in contrast. It is shown that the solutions behave the same as Newtonian flow as the rotor speed goes beyond 12 rpm. With an increase of temperature, the apparent viscosity of AN/AEMP copolymer solutions shows a trend of decrease. The changes of the apparent flow activation energy of solutions calculated by Arrhenius equation become less prominent along with the changes of the molecular weight of AN/AEMP copolymers. The apparent flow activation energy of the copolymer solutions increases continuously with an increase of copolymer concentration. The viscosity of copolymer solutions decreases continuously as the concentrations of KCl and NaCl up to 0.02 mol L^?1, and then it increases. the apparent flow‐activation energy of AN/AEMP copolymer solutions shows an obvious trend of decrease with addition of alkali salts and the changes of the apparent flow‐activation energy of solutions containing NaCl are more prominent than those of solutions containing KCl. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2972–2976, 2006