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Coefficients of dynamic friction as a function of temperature, pressure,

and velocity for several polyethylene resins

Article in Polymer Engineering and Science · April 1995

DOI: 10.1002/pen.760350702

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Mark A. Spalding Kun S Hyun

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 Coefficients of Dynamic Friction as a Function
of Temperature, Pressure, and Velocity
for Several Polyethylene Resins
MARK A. SPALDING and KUN S. HYUN
Designed ThermoplasticsResearch Laboratory
The Dow Chemical Company
Midland, Michigan 48667
The coefficient of dynamic friction is often the controlling factor for solids
conveying, pressure generation, and thermal decomposition of a resin in the feed
section of a single-screw plasticating extruder. The coefficients of friction are,
however, very poorly understood, and the interpretation of the measurements are
complicated by the dissipation of frictional energy at the sliding interface. A new
instrument was recently built to help understand dynamic friction, and a numeri-
cal technique was developed to estimate the interface temperature. Coefficients of
dynamic friction for several polyethylene resins are presented in this paper as a
function of the surface temperature, pressure, and velocity. The relationship of the
data with respect to the extrusion process is discussed.

INTRODUCTION forms of the theory (5) use bulk density as a function

of pressure and temperature (6) and coefficients of
n a plasticating extruder, the coefficient of dynamic
I friction is in many cases the controlling factor for
solids conveying. pressure generation, thermal de-
friction as a function of pressure, temperature, and
velocity (3).Frictional coefficients at conditions typi-
cal of extrusion, however, are generally not available
composition of the resin, and flow surging at the die.
because of the difficulty in measuring them and the
The coefficient of friction is, however, very poorly
lack of precise measuring devices.
understood and very difficult to measure. Moreover,
Several types of friction coefficients are commonly
interpretation of experimental data are complicated
measured. They include coefficients of dynamic (3).
by the dissipation of frictional energy at the sliding
static, and storage friction (6). Each coefficient is
interface. This energy flux at the interface makes it
used for different applications, and they must not be
extremely difficult to determine the coefficient a s a
interchanged. The coefficient of static friction is the
function of temperature, pressure, and velocity at
ratio of the frictional force on a body divided by the
conditions of extrusion.
load force perpendicular to the frictional surface at
A new friction-measuring device has been designed
static equilibrium. If the frictional force is increased
and fabricated based on a first generation machine
by a differential amount, then the body will start to
built at Rensselaer Polytechnic Institute by C. I.
move. If the body is moving, the ratio of the frictional
Chung (1.2). The unit is capable of studying the
force to the load force is the coefficient of dynamic
forces, resulting from frictional and viscous drag, on
friction. This coefficient is typically lower than that
a small slab of polymer at conditions typical of extru-
for the static case. The dynamic coefficient is the type
sion. With this equipment and a numerical technique
of coefficient of interest to extrusion. It will be re-
for computing the interface temperature (3),the coef-
ferred to in this paper as the coefficient of dynamic
ficient can be measured as a function of temperature,
friction or simply coefficient of friction. Storage
pressure, and velocity.
friction describes how pressure is transmitted or dis-
sipated in a confined column of particles; it is a
LITERATURE REVIEW combination of friction between particles and friction
The accepted solids conveying mechanism for the between the particles and the chamber wall.
feed section is based on the theory developed by All friction measuring devices measure the temper-
Darnel1 and Mol (4). The basic theory assumes con- ature at a location away from the interface where the
stant density for the solid bed and constant coeffi- sliding is occurring. At the sliding interface, frictional
cients of dynamic friction for both the barrel and dissipation of energy will result in temperatures at
screw root surfaces in order to estimate solids con- the interface that are considerably higher than those
veying and power consumption. More sophisticated temperatures measured. This effect can be quite large

POLYMER ENGINEERING AND SCIENCE, MID-APRIL 1995, Yo/. 35, No. 7 557
 Mark A. Spalding and Kun S. Hyun
at conditions typical of extrusion. Frictional heat dis- Force, F
sipation at the interface is directly proportional to
pressure, coefficient of friction, and the velocity (3).

RESINS
Six different commercial grade polyethylene (PE)
resins were used for this study. The resins studied
had varying solid densities and were as follows: 1)
ultra low-density PE (ULDPE) with a density of 0.912
g/cm3, 2 ) linear low-density PE (LLDPE), density of Torque l? Required
0.920 g/cm3, 3) low-density PE (LDPE), density of
0.922 g/cm3, 4) LLDPE with a density of 0.935g/cm3, to Keep Roll Moving
5) high-density PE (HDPE), density of 0.9495 g/cm3,
and 6) HDPE resin with a density of 0.951 g/cm3. All
resins were manufactured by The Dow Chemical
W
Fig. 1 . Schematic of thefriction measuring instrument.
Company and were in the form of spheroid-shaped
pellets with a n average diameter of about 4 mm. The
HDPE resin with a density of 0.9495 g/cm3 was using a n implicit finite difference technique (3). This
designed for grooved-barrel extruders. All other resins technique was verified experimentally using acryloni-
were designed for smooth-barrel extruders. trile-butadiene-styrene polymer (ABS). Without the
calculation of the interface temperature, the effects of
EQUIPMENT pressure, temperature, and velocity on the coefficient
The device used to measure the coefficient of fric- cannot be separated. The calculated interface temper-
tion was described in a previous paper (3). and a ature will be referred to as simply the temperature in
schematic of the instrument is shown in Fig. 1. PE the remainder of the paper.
pellets were placed in a 12.9 cm2 (5.08X 2.54 cm)
sample chamber positioned above a 30.48 cm diame- COEFFICIENTS OF DYNAMIC FRICTION
ter rotating roll. The force applied to the pellets by a The coefficients of dynamic friction for the PE resins
plunger was set by the operator and was also mea- were measured as a function of temperature at pres-
sured by a load cell. In order to keep the roll speed sures of 0.69, 3.45, and 6.9 MPa and at roll velocities
constant, a torque was applied to the roll shaft. This of 7.6, 15.2, and 30.5 cm/s. The coefficients and
torque was measured by a sensor and the value was trend curves are shown by Figs. 2 through 19. The
used to calculate the coefficient of friction. The coeffi- curves fitted to the data on these Figures are only
cient is defined a s the frictional force at the roll meant to aid in the identification of the trends. As
surface (obtained from the torque measurement) di- indicated by these Figures, the coefficients of dy-
vided by the applied load. Calculation of the coeffi- namic friction are complicated functions of tempera-
cient was defined previously (3).All instrument sen- ture, pressure, velocity, and resin type.
sors and devices were controlled and monitored using For all resins, the coefficient of friction increased
a CAMILE data acquisition and control system with increasing velocity. This increase with velocity
(3,7,8).(Camile is a trademark of The Dow Chemical was the largest for the ULDPE, LLDPE, and LDPE
Company.) resins. The coefficients for the HDPE resins did not
The surface treatment of the roll with the resin will increase with increasing velocity to the same extent.
affect the coefficient of friction. For these experi- This increase in the coefficients with increasing veloc-
ments, the roll was first cleaned to a shiny finish. ity is very beneficial to stable solids conveying in an
Next, the test resin was added to the chamber and a extruder. This topic will be discussed in detail later.
trial experiment was performed. This experiment was The coefficients of friction decreased with increas-
used to condition the roll only and thus the frictional ing pressure for all resins. Like the effect of velocity
data were discarded. The sample was then removed on the coefficient, the ULDPE. LLDPE, and LDPE
and replaced with fresh resin. Numerous trial experi- resins showed stronger dependencies with pressure
ments were performed before the frictional measure- as compared with the HDPE resins.
ments were collected. Coefficients measured during The coefficients depended on temperature for all
the trial experiments tended to decrease slightly with resins. The effect of temperature was consistent for
consecutive measurements. Trial experiments were all resins at high pressure. At a pressure of 6.9 MPa,
continued until several experiments showed no trends the coefficients for the resins decreased nearly lin-
with replicate measurements. early with increasing temperature. The coefficient for
The roll surface temperature underneath the poly- the ULDPE did, however, increase slightly with in-
mer sample is not practical to measure, but it can be creasing temperature at temperatures above about
calculated based on the experimental data and 115"C, and the coefficient for the HDPE resin with a
steady-state, two-dimensional heat transfer equa- density of 0.9510 g/cm3 increased slightly with in-
tions derived and solved for the equipment geometry creasing temperature in the range of 30 to 60°[Link] a

558 POLYMER ENGINEERING A N D SCIENCE, MID-APRIL 1995, Vol. 35, No. 7

 Coeflcients of Dynamic Friction

1.0 1.0

c
c
.2
0
0.8
0
= 30.5 cm/S
= 15.2 cm/s
= 7.6 cm/s
.s
J
0
0.8
0
= 30.5 cm/s
= 15.2 cm/s
= 7.6 cm/s
LE
~

0
0.6
0

5 0
0.6
0

3 3

.r(
0.4 .4
5 0.4
0 0
E 5
Q1 0.2 8 0.2
8 0

0.0 I I I I 0.0
40 60 80 100 120 1 20 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
Fig. 2. Coemient of dynamic friction for ULDPE (0.912 g / Fig. 5 . Coefficient of dynamic fiction for LLDPE (0.920 g /
cm31 a t a pressure of 0.69 MPa. cm3) a t a pressure of 0.69 MPa

1.0 1 1 .o
I

I I I I
Velocity Velocity

0
= 30.5 cm/s
= 15.2 cm/s
,5
4
0
0.8
0
= 30.5 cm/s
= 15.2 cm/s
= 7.6 cm/s 0 = 7.6 cm/s
0
2
b
0 o.6 1 ru
0
0.6

0.0 1 I I I I I 4 0.0 ; I I I 1 I
20 40 60 80 100 120 140 20 40 60 80 100 120 I :O
Calculated Interface Terriperat iirt:, "C Calculated Interface Temperature, "C
Fig. 3. Coeflcient of dynamic friction for ULDPE (0.912 g / Fg. 6. Coeffcient of dynamic fiction for LLDPE (0.920 g /
cm3) a t a pressure of 3.45 MPa. cm3) a t a pressure of 3.45 MPa.

1.o 1.0

Velocity Velocity
.sc
3
0.8 = 30.5 cm/s
0 = 15.2 cm/s
.g
3
0.8 = 30.5 cm/s
0 = 15.2 cm/s
0 0 =
0
E 0.6
7.6 cm/s
is
~ 0.6
0 = 7.6 cm/s

0 0
4 3
5
.A
0.4
.4
$ 0.4
.-0 2 0
2
8 0.2 0.2
0 8
0.0 I I I I I 0.0
20 40 60 80 100 120 140 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
Fg. 4. Coefficient of dynamicfictwn for ULDPE (0.912 g / Fg. 7. Coefficient of dynamic friction for LLDPE (0.920 g /
cm3) a t a pressure of 6.9 MPa cm3) a t a pressure of 6.9 MPa.

POLYMER ENGlNEERlNG AND SCIENCE, MlD-APRIL 1995, Vol. 35, No. 7 559
 Mark A. Spalding and K u n S . H y u n

0.6

0.8 5
.r(
J
0
0.4
0.6 b-4
0
+J
0.4 5
.r(

0.2
30
Q
0.2 0
V

0.0 I
20 40 60 80 100 120 140
0.0
20 40 60 80 100 120 1 .O
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
Q. 8. Coefficient of dynamicfriction for LDPE (0.922g/ cm3) Q. 11. Coefficient of dynamic friction for D P E (0.935 g /
at a pressure of 0.69 MPa. cm3) a t a pressure of0.69 MPa.

0.6

I I
Velocity
= 30.5 cm/s
.r(

3
E 0.8- 5
.d

J
0 = 15.2 cm/s
0 0 0 = 7.6 cm/s
8
~ 0.6 - %I
0.4

0 0
J 3

5 0.4 - .-5
s
.r(

s 0 0 0.2

8 0.2-
0
a,
0
0

0.0 ! I I I I 0.c
20 40 60 80 100 120 140 20 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
F'ig. 9. Coefficient of dynamicfriction for LDPE (0.922g/ cm3) Fig. 12. Coefficient of dynamic friction f o r LLDPE (0.935 g /
a t a pressure of 3.45 MPa. ern3) a t a pressure of 3.45 MPa.

1.o 0.6
Velocity
= 30.5 cm/s
.g
3
0.8 = 30.5 cm/s .r(
3
0 = 15.2 cm/s
= 7.6 cm/s
0 0 = 15.2 cm/s 0 0

L2
~ 0.6
n = 7.6 cm/s
%I
0.4

0 0
3 3

.e
50 0.4 5
.r(
0.2
$ 30
Q
8
Q 0.2
s
n.a 0.0 I I I I I
40 60 80 100 120 140 20 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
Fg. 10. Coemient of dynamicfriction for LDPE (0.922 g / Rg. 13. Coefficient of dynamic friction for LLDPE (0.935 g /
cm3) a t a pressure of 6.9 MPa. cm3) a t a pressure of 6.9 MPa.

560 POLYMER ENGINEERINGAND SCIENCE, MID-APRIL 1995, Vol. 35, NO. 7

 Coeflcients of Dynamic Friction

-.- I

1
d
0
.3 5
.rl
4
0
0.4
0.4
Q+
0
4
5
-3

0 0.2
50
.H
0.2
r;:

v I
0.0 1 I I I I I
20 40 60 80 100 120 140 20 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
Rg. 14. Coefficient of dynamicfictionfor HDPE (0.9495 g / 0.17. Coeffwient of dynamic friction f o r HDPE (0.951 g /
cm3)at a pressure of 0.69 MPa. cm3)at a pressure of 0.69 MPa.

0.6 0.6

4
5
.r( 5
.rl

4
= 30.5 cm/s
0 = 15.2 cm/s
g 0.4
0
0.4
0
0 = 7.6 cm/s
%.I +I
0 0
4

5
.,-I
0 0.2
G.I
%
u
0
0

0.0 0.0 I , I
I 40 60 80 100 120 1 0
Calculated Interface Temperature, "C
Q. 18. Coefficient of dynamicficlion for HDPE (0.951 g /
cm3)at a pressure of 3.45 MPa.

0.6 I 0.6

0.4 I 5
.r(

4
0
&
%.I
0
4

50
-r(
0.4

0.2
0 =
Velocity
= 30.5 cm/s
0 = 15.2 cm/s
7.6 cm/s

0,
0
u
0.0
20 40 60 80 100 120 1 40 60 80 100 120 140
Calculated Interface Temperature, "C Calculated Interface Temperature, "C
m. 16. Coeffxient of dynamicfrictionfor HDPE (0.9495 g / 0.19. Coefficient of dynamic frictionfor HDPE (0.951 g /
cm3)at a pressure of 6.9 MPa. cm3)at a pressure of 6.9 MPa.

POLYMER ENGINEERING A N D SCIENCE, MID-APRIL 1995, Vol. 35, N o . 7 561

 Mark A. Spalding and Kun S. Hyun

pressure of 3.45 MPa, the effect of temperature for the polymer-metal interface temperature approaches
the resins was mixed. For example, the coefficients or exceeds the melting temperature or the glass tran-
for the ULDPE, LLDPE, and LDPE resins decreased sition temperature.
with increasing temperature, and the coefficients for As previously discussed (3). the velocity of the solid
the HDPE resins increased with increasing tempera- bed relative to the metal surfaces is considerably
ture up to about 80°C and then decreased with in- higher at the barrel wall than at the screw root. The
creasing temperature. At a pressure of 0.69 MPa, the coefficients of friction for these resins increase with
coefficients for the ULDPE have minimum values for increasing velocity, and thus for a given pressure and
the temperature range, LLDPE with a density of 0.935 temperature the coefficient will be higher at the bar-
g/cm3 and LDPE (velocity dependent) have maxt re1 interface than at the screw root interface. The
mum values for the temperature range, and the HDPE increase in the coefficient with velocity is advanta-
resins increased with increasing temperature. geous to solids conveying. The temperatures at the
Relationships between polymer structures and the interfaces, however, can be quite different.
coefficients of friction are possible, but they are be- The PE friction data are consistent with their rela-
yond the scope of this paper. The frictional data as it tive ease of solids conveying during extrusion. The
relates to solids conveying in plasticating extruders is ULDPE, LLDPE, and LDPE resins under most situa-
discussed next. tions forward well during extrusion, and thus there is
no loss of feeding and there are no wide variations in
Relations to Solids Conveying the first extruder zone pressures. Other problems
Solids conveying depends on the frictional forces downstream from the solids conveying section may,
exerted on a differential slab of solids in the feed however, cause flow surging at the die for these resins.
channel (4). In general, the force acting on the slab at The coefficients for these resins are fairly high and
the barrel-solids interface (force acting in the direc- vary to a large degree with velocity and pressure.
tion of flow) must be greater than that at the screw Because of this wide variation, process conditions are
root-solids interface (force acting opposite to the flow easily found where the solids convey well. The HDPE
direction). For this condition, pressure will increase resins, however, have coefficients that are consider-
in the feed channel. If the force at the barrel interface ably lower than the other PE resins. These lower
is only slightly greater than that at the screw root, coefficients and the low levels of variation with veloc-
then the solids will convey but at reduced rates. If the ity, temperature, and pressure in many cases require
force at the screw root interface is greater than that the extruder system to be optimized to a higher de-
at the barrel, then the solids must convey via pres- gree as compared with those machines using low-
sure: i.e., a pressure drop will accompany any for- density resins. To increase the rates and maintain
warding of the solid bed. After a very short distance at stable extrusion, some converters prefer to extrude
this condition, however, the pressure will drop to zero HDPE resins using grooved-barrel machines, creating
and the solids will no longer convey. At this point the a drag force at the barrel surface that is considerably
frictional force will change because the pressure has higher than that at the screw root.
dropped to near zero, and the solids will again convey
via frictional forces. The net result is a pulsing poly- SUMMARY
mer flow from the solids conveying section to the
The coefficients of dynamic friction for several PE
transition section, causing unacceptable flow surging
resins were measured as a function of temperature,
in the extruder and at the die. These forces at the
pressure, and velocity. The data indicated that the
interface are directly related to the coefficient of dy-
coefficients increased with increasing velocity, de-
namic friction.
creased with increasing pressure, and were compli-
If the coefficients were such that the forwarding
cated functions of temperature.
forces at the barrel interface were always greater
than the drag forces at the screw root interface, then
the conveying of the solids will always occur. If the ACKNOWLEDGMENTS
coefficient of friction does not show a minimum The authors acknowledge the help of Myron Mauer
and/or a maximum in the temperature processing and Brian Hilton in obtaining some of the raw data,
range (excluding end temperatures) and if the coeffi- and Prof. C. I. Chung of Rensselaer Polytechnic Insti-
cient increases with increasing velocity, then the tute for his input into the design of the friction mea-
above conditions will be easily satisfied via processing suring instrument.
conditions and thus solids conveying will occur. But,
if a minimum, maximum, or the coefficient decreases REFERENCES
with increasing velocity, then solids conveying can be
difficult because there is a possibility for the drag 1. C. I. Chung, W. J. Hennessey. and M. H. Tusim, Polym
Eng. Sci., 17, 9 (1977).
force on the slab at the screw root interface to exceed 2. E. M. Mount, PhD thesis, Rensselaer Polytechnic Insti-
that at the barrel wall. Rheological forces at the barrel tute, Troy, N.Y. (1979).
wall also contribute to solids conveying (9). These 3. M. A. Spalding, D. E. Kirkpatrick, and K. S . Hyun, Polym
forces become important when the temperature of Eng. Sci., 33. 423 (1993).

562 P O L Y M E R E N G I N E E R I N G A N D SClENCE, MID-APRIL 1995, Vol. 35, NO. 7

 Coefficientsof Dynamic Friction
4. W. H. Damell and E. A. J. Mol, SPEJ., 12,20 (1956). 7. G. R. Strickler, Chem Eng. h o g . , 82, 50 (1986).
5. S. R. Strand, M. A. Spalding, and K. S. Hyun. PIat. Eng., 8. M. A. Spalding and P. T. DeLassus, J . P l a t Film Sheet, 6,
July 1992, p. 17. 292 (1990).
6. K. S. Hyun and M. A. Spalding, Polym Eng. Sci.,30,571 9. C. I. Chung, SPE J., 26.32 (1970).
(1990).
Received July 8,1993

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