Two copolymers of poly(methy1 methacrylate) with 3% and 10??0 ethyl acrylate, respectively, were extruded and calendered, with the same line speed and roll temperatures. The residual stresses and anisotropies, induced by the complex processing deformations and temperature variations, were characterized by monitoring the dimensional changes and sample curvatures resulting from subsequent heat treatments. In both copolymers, two distinct recovery regimes were observed: heat treatments just below Tg caused relaxation of residual thermal stresses and at temperatures above Tg led to recovery of chain extended orientations. It was found that the similar processing conditions induced similar residual thermal stresses in the two copolymers, but the higher viscosity of the 3% EA sheet led to greater residual orientations. Across the width of the sheets, little variations were seen in the thermal stresses, but orientations were lower at the edges. Some curvature changes observed following heat treatment well below Tg, were interpreted as resulting from aging effects.
JNTRODUCTIONmethod used in the present analysis, the recovery of xtruded and calendered sheet is produced for a and for subsequent thermoforming. Calendering involves the cooling of an extrudate around a series of rolls to produce flat sheets of uniform thickness. The large thermal gradients and imposed strains during calendering may lead to unacceptably high levels of residual stresses in the fiial sheet, causing warping or even promoting failure (1-4). High levels of preferred orientation lead to anisotropy in mechanical properties (5) and may also present difficulties during subsequent processing at temperatures where orientations relax. For these reasons, knowledge of the levels of residual thermal stresses and orientations in calendered plastics is desirable. Furthermore, an understanding of the factors that are important in determining these levels presents a route towards producing an optimized microstructure, suitable for subsequent processing. In the longer term, control of orientation and residual stresses may also prove to be a useful tool in polymer engineering. Before an analysis can be made of the effects of calendering conditions on residual stress and orientation distributions, procedures must be developed to characterize fully these distributions. Both residual stresses and orientations are known to relax at elevated temperatures as a polymer recovers. In the E W .de range of uses, both directly in sheet form 'Corresponding author. E-mail. d.h.isaa&swansea.ac.uk samples is monitored as they are-heat treated across a range of temperatures, including that associated with the glass transition. At elevated temperatures, the polymer network approaches an equilibrium state due to increased molecular mobility. This process is driven by the dissipation of elastic and inelastic strain energy, stored during calendering. Polymer recovery manifests itself in these materials in the form of changes in length and curvature, which are readily measurable. Thes...