Numerical flow simulations play an important role in polymer processing. One of the essential prerequisites for accurate and precise flow simulations is to obtain accurate materials functions. In the framework of the generalized Newtonian fluid model, one needs to obtain shear viscosity as a function of the rate-of-shear and temperature—as determined by rheometry—and then fitted to a mathematical model. Often, many subjectively perform the fitting without paying attention to the relative quality of the estimated parameters. This paper proposes a unique iterative algorithm for fitting the rate-of-shear and temperature-dependent viscosity model under the time–temperature superposition (TTS) principle. Proof-of-concept demonstrations are shown using the five-parameter Carreau–Yasuda model and experimental data from small-amplitude oscillatory shear (SAOS) measurements. It is shown that the newly proposed iterative algorithm leads to a more accurate representation of the experimental data compared to the traditional approach. We compare their performance in studies of the steady isothermal flow of a Carreau–Yasuda model fluid in a straight, circular tube. The two sets of parameters, one from the traditional approach and the other from the newly proposed iterative approach, show considerable differences in flow simulation. The percentage difference between the two predictions can be as large as 10% or more. Furthermore, even in cases where prior knowledge of the TTS shifting factors is not available, the newly proposed iterative approach can still yield a good fit to the experimental data, resulting in both the shifting factors and parameters for the non-Newtonian fluid model.

Flow distribution channels in extrusion dies are typically designed to assure uniform fluid velocity, pressure and temperature in the outlets. To ensure this uniformity, it is desirable to have the fluid melt to reach a steady state temperature in the entrance channel before entering the die body. This paper numerically investigates the temperature distribution of the fluid melt in the entrance channel. Analytical solutions of the velocity and finite element solutions of temperature distribution in Poiseuille flows of polypropylene melt with the Casson rheology model were derived and presented. In the velocity solution, the critical point that separates the core and the remaining parts in the flow was calculated by using the inlet flow rate and the yield stress in the Casson model. The velocity distribution was then substituted into the convective heat equation for temperature distribution simulations. A finite difference scheme was used to obtain the temperature distribution profiles along the flow direction in a parallel-plate, while the finite element model was used to model the flow temperature in circular tubes. The main outcome is the parametric analyses of the effect of various parameters such as radius, wall temperature, inlet temperature, and pressure drop to the optimal length of the channels required for the flow temperature to reach the steady state.

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