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In this work, viscoelastic, isothermal extrusion film casting modeling utilizing 1D membrane model and modified Leonov model was performed in order to understand the role of viscoelastic stress state at the die exit on the polymer melt film stretching in the post die area. Experimental data for LDPE and theoretical predictions based on the eXtended Pom-Pom (XPP) model taken from the open literature were used for the validation purposes. It was found that predicting capabilities of 1D membrane model utilizing XPP and modified Leonov model are comparable for the given processing conditions and material. Consequent theoretical parametric study revealed that increase in the viscoelastic stress state at the die exit, characterized as the ratio of second and first normal stress differences, -N2/N1, leads to increase in neck-in phenomenon. This suggests that specific attention should be paid to optimization of the extrusion die design in order to stabilize polymer melt film stretching in the post die area.

Effect of viscoelastic stress state at die exit on extrusion film casting process: Theoretical study