The mathematical model of polymer plastication in a reciprocating screw injection molding machine is presented. It takes into account all characteristic features of working of a real injector, such as periodical action of the three zones screw, to-and-from screw motion with controlled stroke, static and dynamic melting, etc. Methods for description of time changes of the solid bed profile in the screw channel during injection cycle as a function of operating parameters were developed. Ways of determination of pressure and temperature profiles in the screw channel were also discussed. Methods of caculation of the most important flow characteristics such as plasticizing capacity, power requirements, screw torque, energy consumption were analyzed. Results were presented in a form, which is most convenient for numerical applications in computer simulation programs.

A computer program for the simulation of polymer plastication in screw injection molding machine created on basis of the theoretical model presented in part 1 of this paper is discussed. As simulation examples various process characteristics, e. g. solid bed, pressure and temperature profiles, are computed using the material parameters for high density polyethylene and three-zones-screw of diameter 20 mm. Effects of different geometric and operating parameters on plastication course are also demonstrated. Simulation results with respect to the screw rotation time are compared with experimental data measured for low density polyethylene, polypropylene, polystyrene, polyoxymethylene and polyamide 6. It was found that the computer program reflects correctly all features of a true plasticating system in injection molding machine. It provides also good agreement of model predictions with experimental data.

Two semiempirical models of generalized Newtonian fluid are discussed. Special attention was focused on the stress dependent model based on the free volume theory. However, the strain‐rate dependent model in form of a modified viscosity function resulting from Oldroyd equation is also presented. Both models (along with specific cases) reflecting pseudoplastic or dilatant behavior of liquids in shear flows are generalized to multimode models (defined as products of two or more basic models), which are able to describe quantitatively the behavior of more complex systems, for example, systems with pseudoplastic and dilatant properties in different shear stress (shear rate) ranges. A number of practical examples for viscosity curves of non‐Newtonian fluids described by these models are given. The questions of inverse models and model efficiency are also discussed. POLYM. ENG. SCI., 58:1446–1455, 2018. © 2017 Society of Plastics Engineers

Analytical expressions for the isothermal, two-dimensional flow of an Ellis fluid in rectangular channel have been derived. The obtained solution describes also the flow of Newtonian and power law fluids as the specific cases. This solution was further adapted for the theoretical analysis of the temperature and pressure effects during the non-isothermal flow of Ellis fluid. The results obtained both for isothermal and non-isothermal flow conditions have been verified numerically.