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All Journal Makara Journal of Technology
Ku Ishak, Ku Marsilla
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Chemical Engineering, Chemistry & Bioengineering Civil Engineering, Building, Construction & Architecture Electrical & Electronics Engineering Engineering Materials Science & Nanotechnology Mechanical Engineering

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Journal : Makara Journal of Technology

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Effect of Different Pressures on Polymer Flow at a Contraction Path: A Real-Time Numerical Approach Azmi, Muhammad Afiq; Ariff, Zulkifli Mohamad; Shuib, Raa Khimi; Rusli, Arjulizan; Ku Ishak, Ku Marsilla; Shafiq, Mohamad Danial; Hamid, Zuratul Ain Abdul; Zakaria, Zulfirdaus; Abu Bakar, Muhamad Husaini; Abdullah, Muhammad Khalil
Makara Journal of Technology Vol. 28, No. 3
Publisher : UI Scholars Hub

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The complexity of polymer flow through a contraction arises from the simultaneous occurrence of shear and elongational strains near the entrance of the contraction path (die). Although this phenomenon has been extensively studied, the effect of plunger motion on the flow toward the contraction path remains underexplored. This study investigated the rheological behavior of thermoplastic polymers at a contraction flow path to enhance the understanding of their flow and rheological behavior, including variations in velocity, pressure, viscosity, and shear rate under varying loads. Polypropylene (PP), a semicrystalline polymer with a low melting point, was used as the test material. The operating temperature was set to 180 °C, and the displacement of the plunger, marked with black lines at its initial and final heights, was recorded under loads of 0.3, 0.6 and 0.85 MPa. The displacement rates were analyzed using MATLAB. A dynamic mesh approach in ANSYS 19 was employed to simulate the real-time motion of the plunger, incorporating a user-defined function developed in C language to control the dynamic boundary motion. The numerical approach successfully simulated the rates of plunger displacement (speed) and predicted the viscosity of PP within the paths (barrel and die). Results indicated that the plunger speed increased with pressure. The pressure generated by the plunger created a driving force that overcame the resistance to flow within the barrel. Higher pressure from the plunger resulted in a greater driving force, which increased the flow rate of the polymer melt through the barrel. On the other side, as the polymer melt flowed from a large cross-sectional area to the contraction flow area, the velocity of the polymer molecules increased, resulting in a pressure drop in the PP melt. Polymer molecules became oriented and stretched in the flow direction upon entering the contraction area, further increasing the shear rate. Consequently, the reduced cross-sectional area in the contraction increased the flow rate, elevated the shear rate, and decreased the viscosity, facilitating polymer flow through the contraction.
Aerodynamics and Heat Transfer in Polymer Blown Film Processing: Experimental and Numerical Investigation Zulbakri, Mohammad Luqman; Mat. Rautin, Nur Atiqah; Shuib, Raa Khimi; Ku Ishak, Ku Marsilla; Abdul Hamid, Auratus Zuratul Ain; Shafiq, Mohamad Danial; Idroas, Mohamad Yusof; Abdullah, Muhammad Khalil
Makara Journal of Technology Vol. 29, No. 3
Publisher : UI Scholars Hub

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The effects of airflow dynamics, heat transfer, and mechanical properties on the HDPE blown film extrusion process were examined using a single-lip air ring with a fixed compressed-air valve opening angle of 10°. Reynolds numbers ranging from 9175 to 25911 were analyzed to understand their impact on cooling efficiency, bubble morphology, and film properties. Numerical simulations employing the Standard k−ω turbulence model in ANSYS FLUENT v2023, with mesh refinement achieving y+ ≈ 1, captured detailed flow and heat transfer behavior. Results showed that higher Reynolds numbers significantly enhanced the heat transfer coefficient, with values increasing from 1096 W/m²·K at Reynold number of 9175 to 1438 W/m²·K at Reynolds number of 25911, reducing the axial cooling distance by up to 30%. This rapid cooling improved the cooling rate but led to a reduced lay-flat width (from 29.10 cm at a Reynolds number of 9175 to 27.50 cm at a Reynolds number of 25911) and thicker films. The tensile stress decreased from 25.25 MPa at a Reynolds number of 9175 to 20.84 MPa at a Reynolds number of 25911, reflecting the impact of turbulence on the polymer chain alignment. These findings emphasize the trade-offs between enhanced cooling efficiency and material properties, offering critical insights for optimizing blown film extrusion processes for improved quality and operational performance.
Co-Authors Abdul Hamid, Auratus Zuratul Ain Abdullah, Muhammad Khalil Abu Bakar, Muhamad Husaini Ariff, Zulkifli Mohamad Azmi, Muhammad Afiq Hamid, Zuratul Ain Abdul Idroas, Mohamad Yusof Mat. Rautin, Nur Atiqah Rusli, Arjulizan Shafiq, Mohamad Danial Shuib, Raa Khimi Zakaria, Zulfirdaus Zulbakri, Mohammad Luqman