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Extrudate swell of industrial-grade high-molecular mass high-density polyethylenes (HDPEs) in flat/slit dies is studied using both experiments and simulations. The experimental set-up consists of an optical micrometer to measure the extrudate dimensions and a pair of radiation heaters to control the extrudate temperature outside the die attached to the capillary rheometer. The simulation of extrudate swell phenomenon is carried out by using a well-known integral K-BKZ model. The effects of several rheological characteristics, die characteristics, and processing conditions on swell measurements are studied systematically, and the corresponding two-dimensional, steady-state numerical predictions are presented in this paper. This study includes the effects of polymer molecular characteristics, apparent shear rate, die geometrical characteristics (length to die gap (L/H) and width to die gap (W/H)), and distance from the die exit. It is found that the integral K-BKZ model predicts well both the width and thickness extrudate swells. Extrudate swell measurements demonstrate that the thickness swell is predominant in comparison with width swell.

Extrudate Swell of High Density Polyethylenes in Slit (Flat) Dies