Numerical and experimental studies for gas assisted extrusion forming of molten polypropylene

In this study, the experiments of gas‐assisted extrusion (GAE) for molten polypropylene were carried out under different gas pressures, the different extrudate deformations and sharkskin defects of melt were observed. To ascertain the effects of gas on melt extrusion, non‐isothermal numerical simulation of GAE based on gas/melt two‐phase fluid model was proposed and studied. In the simulations, the melt extruded profile, physical field distributions (velocities, pressure drop, and first normal stress difference) were obtained. Numerical results showed that the deformation degree of melt increased with increasing gas pressure, which was in good agreement with experimental results. It was demonstrated that the influence of gas pressure on the melt extrusion could be well reflected by GAE simulation based on gas/melt two‐phase fluid model rather than simplified‐GAE (SGAE) based on full‐slip wall boundary condition used in the past time. Experimental and numerical results demonstrate that the gas pressure induced first normal stress difference is the main reason of triggering flow behavior changes, extrudate deformations, and sharkskin defects of melt. Therefore, the reasonable controlling of gas pressure is a key in practice of GAE, and the gas layer and its influence should be considered in GAE numerical simulation. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42682.