Studies on melt spinning. VIII. The effects of molecular structure and cooling conditions on the severity of draw resonance

The effects of molecular structure and cooling conditions on the severity of draw resonance was investigated by carrying out carefully controlled melt spinning experiments. For the study, two types of polymeric materials were used: one which exhibits viscoelastic behavior (high-density polyethylene, polypropylene, and polystyrene), and the other which exhibits almost Newtonian behavior [nylon-6 and poly(ethylene terephthalate)]. In order to investigate the effect of cooling on the severity of draw resonance, different methods of cooling the molten threadline were employed. In one set of experiments, isothermal chambers of various lengths (3, 6, and 12 in.) were attached to the spinnerette face, so that the molten threadline, upon exiting from the spinnerette, began to cool in the ambient air only after it had passed through the isothermal chamber. This method of cooling is called “delayed cooling,” providing both an isothermal region (inside the isothermal chamber) where only stretching occurs, and a nonisothermal region (outside the isothermal chamber) where both stretching and cooling occur simultaneously. In other experiments, the temperature profile of the molten threadline was controlled by adjusting the temperature of the heated chamber. This method of cooling provides a gradual drop of the threadline temperature, compared to the more sudden drop when spinning into a cold environment provided at the spinnerette exit. The severity of draw resonance was recorded on movie film, and the thread tension was measured with a low-force load cell transducer and recorded on a chart recorder. The temperature of the threadline along the spin direction was measured using a fiber optical probe attached to a Vanzetti Infrared Thermal Monitoring System (Model TM-1). It was found that the severity of draw resonance depended on the molecular structure and the way the molten threadline was cooled. Of particular interest is the observation that, for the viscoelastic materials investigated, cooling destabilized the molten threadline outside the isothermal chamber. This gave rise to more severe resonant behavior, at and above the critical draw-down ratio, in contradiction to the theoretical prediction by Fisher and Denn. It was observed, also, that the elasticity of the materials tended to destabilize the molten threadline (i.e., it increased the severity of draw resonance), again in contradiction to the theoretical prediction of Fisher and Denn. It is believed that morphological changes of polymers may play an important role in the occurrence of draw resonance when a melt threadline is stretched under cooling. Our study indicated that a good understanding of draw resonance of viscoelastic fluids requires more careful study than the classical hydrodynamic stability analysis reported by Fisher and Denn. They based their analysis on several convenient and yet unjustified assumptions, and solely on phenomenological considerations. We suggest that future theoretical analysis of draw resonance be carried out by considering a fluid model with a nonlinear memory function in order to properly account for the deformation history of the fluid, and the relaxation and cooling processes in the die swell region and the region below it.