Numerical problems

P3.1

Draw velocity profiles and shear rate profiles for fluids whose power law index values are (a) n=1 (b)

n=0.7 (c) n=0.5 (d) n= 0.25. Assume that the fluid is flowing with a volumetric flow rate of 10 cm 3

per second through a round tube of radius 2 mm and length 8 mm when a pressure of 1440000 Pa is

applied. Comment on the shape of the profile. Assume power law constant, K=166000 Pa sn.

Data:

R= 2mm = 0.002 m

L= 8 mm = 0.008 m

Q= 10 cm3/sec = 0.001 m3/sec=1.66667E-07 m3/s

K=166000 Pa sn

ΔP=1440000 Pa

Solution

For a power law fluid, the velocity of fluid stream flowing through a cylindrical tube is given by

where

In order to calculate maximum velocity, umax and velocity at different radii between 0 mm and 2 mm,
“u’’ assume various “r” values. The computed values of umax and u are shown in Table P-3.1.

1
 Table P-3.1: Computed values of umax and u

n value umax m/s

1 0.001084337
0.7 0.000924515
0.5 0.000783858
0.25 0.00055299
radius, n=1 n=0.7 n=0.5 n=0.25
r mm u, m/s u, m/s u, m/s u, m/s
2 0 0 0 0
1.8 0.00020596 0.00020883 0.000212464 0.000226455
1.6 0.00039024 0.000386992 0.000382592 0.000371786
1.4 0.00055284 0.000535998 0.000515088 0.000460049
1.2 0.00069376 0.000657474 0.000614656 0.000509989
1 0.000813 0.000753182 0.000686 0.000535709
0.8 0.00091056 0.000825065 0.000733824 0.000547327
0.6 0.00098644 0.000875307 0.000762832 0.000551646
0.4 0.00104064 0.000906437 0.000777728 0.000552813
0.2 0.00107316 0.000921552 0.000783216 0.000552984
0 0.001084 0.000925 0.000784 0.00055299
-0.2 0.00107316 0.000921552 0.000783216 0.000552984
-0.4 0.00104064 0.000906437 0.000777728 0.000552813
-0.6 0.00098644 0.000875307 0.000762832 0.000551646
-0.8 0.00091056 0.000825065 0.000733824 0.000547327
-1 0.000813 0.000753182 0.000686 0.000535709
-1.2 0.00069376 0.000657474 0.000614656 0.000509989
-1.4 0.00055284 0.000535998 0.000515088 0.000460049
-1.6 0.00039024 0.000386992 0.000382592 0.000371786
-1.8 0.00020596 0.00020883 0.000212464 0.000226455
-2 0 0 0 0

2
The corresponding velocity profiles are shown in Figure P-3.1

0.0012
n=1
n=0.7
0.0010 n=0.5
n=0.25

0.0008
velocity (m/s)

0.0006

0.0004

0.0002

0.0000
-2 -1 0 1 2

Radius (mm)

Figure P-3.1: Velocity profiles of fluids of different n values at similar flow conditions

The velocity profile become flat at the center as n value decrease as shown in Fig P-3.1 indicating
Non Newtonian nature at n<1.

-------------------------------------------------------------------------------------------------------------------------

P3.2

For the experimental conditions given in problem P3.1, draw shear rate profiles for fluids whose power

law index values are (a) n=1 (b) n=0.7 (c) n=0.5 (d) n= 0.25.

Solution:

For a power law fluid, the shear rate of a fluid stream flowing through a cylindrical tube is given by

3
The values of umax are already computed in Problem P3.1. Thus we can compute the values of shear

rate using above equation. The computed values of shear rate are shown in Table P-3.2.

Table P-3.2: Computed values of shear rate

radius, n=1 n=0.7 n=0.5 n=0.25

r mm shear rate s-1 shear rate s-1 shear rate s-1 shear rate s-1
2
1.084337 1.122625159 1.175787 1.382475
1.8
0.9759033 0.965754959 0.952387 0.907042
1.6
0.8674696 0.816191254 0.752504 0.566262
1.4
0.7590359 0.674444664 0.576136 0.331932
1.2
0.6506022 0.541138061 0.423283 0.179169
1
0.5421685 0.417053768 0.293947 0.086405
0.8
0.4337348 0.303213976 0.188126 0.035391
0.6
0.3253011 0.201032077 0.105821 0.011198
0.4
0.2168674 0.112643593 0.047031 0.002212
0.2
0.1084337 0.041846946 0.011758 0.000138
0
0 0 0 0
-0.2
0.1084337 0.041846946 0.011758 0.000138
-0.4
0.2168674 0.112643593 0.047031 0.002212
-0.6
0.3253011 0.201032077 0.105821 0.011198
-0.8
0.4337348 0.303213976 0.188126 0.035391
-1
0.5421685 0.417053768 0.293947 0.086405
-1.2
0.6506022 0.541138061 0.423283 0.179169
-1.4
0.7590359 0.674444664 0.576136 0.331932
-1.6
0.8674696 0.816191254 0.752504 0.566262
-1.8
0.9759033 0.965754959 0.952387 0.907042
-2
1.084337 1.122625159 1.175787 1.382475

The corresponding velocity profiles are shown in Figure P-3.2. It can be seen from Fig P-3.2 that the
shear rate profile change from linear nature (for Newtonian fluid) to nonlinear nature as n value
4
decrease (Non Newtonian fluids) as shown in Fig P-3.2. Further the shear rate is zero at the center of
the tube and maximum at the wall.

1.50
n=1
n=0.7
1.25
n=0.5
n=0.25
1.00
shear rate, 1/s

0.75

0.50

0.25

0.00

-2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0

radius, mm

Figure P-3.2: Shear rate profiles of fluids of different n values at similar flow conditions

-------------------------------------------------------------------------------------------------------------------------

P3.3

Calculate the true shear rate and shear stress experienced by the melt while flowing through an

injection nozzle of 3.5 mm diameter and 30 mm long. (Data: Volumetric flow rate = 4.5x10-5 m3/s;

K=400 Nsn /m2; n=0.4).

Solution:

True shear rate and shear stress are given by equations

5
 τw = (∆P R)/2L

3𝑛 + 1 4𝑄
𝛾̇ 𝑊 = [ ][ ]
4𝑛 𝜋 𝑅3

Given

Q=4.5x10-5 m3/s;

L=30 mm = 30E-03 m;

R=3.5/2=1.75 mm =1.75E-03 m,

K=400 Nsn /m2 ;

n=0.4

Thus the shear rate at the wall is

3 × 0.4 + 1 4 × 4.5 × 10−5

𝛾̇ 𝑊 = [ ] ×[ ]
4 × 0.4 3.14 × (1.75 × 10−3 )3

𝜸̇ 𝑾 = 14707.25 s-1
From Power law, 𝜏 = 𝐾𝛾̇ 𝑛

= 400 x (14707.25)0.4

τ =18581.15 Pa
-------------------------------------------------------------------------------------------------------------------------

P 3.4

The output of polythene from an extruder is 30 x 10-6 m3/s. If the breaker plate in this extruder has 80

holes, each being 4 mm diameter and 12 mm long, estimate the pressure drop across the plate assuming

the material temperature is 170oC at this point. Data: The shear stress corresponding to the apparent

shear rate at each hole is 1.2 x 105 N/m2.

6
Solution:

Pictorial representation of a breaker plate with representative holes is shown below. Melt comes out

through all the 80 holes. This volumetric flow rate of the coming out through a single hole is given by

Q = (30 x 10-6)/80 = 3.75 x 10-7 m3/s

Fig P-3.3: Breaker plate of an extruder

Each hole may considered as a capillary tube of length 12 mm and diameter 4 mm. Assume that melt
is a Newtonian fluid. Given

4𝑄
𝛾̇ 𝑊 = [ ]
𝜋 𝑅3

4×3.75×10−7
= 3
3.14× [2×10−3 ]

= 59.71 s-1

Shear stress is expressed as τw = (∆P R)/2L

or

2𝐿𝜏𝑤 2 × 12 × 10−3 × 1.2 × 105

= ∆𝑃 =
𝑅 2 × 10−3

7
 = 1.44x106 Pa

-------------------------------------------------------------------------------------------------------------------------

P 3.5

Telephone handsets are produced by injection molding using a six cavity mould shown in fig P-3.1.

The moulder always obtained products with short shots in spite of adjusting machine parameters and

later the problems were referred to the expert. The expert is of the opinion that the problem lies with

the mould, as it is wrongly designed; He suggested modifying the runner diameters appropriately.

What changes are to be made? Justify your answer with suitable calculations.

Fig P-3.4: Six cavity Injection mould.

Solution:

Note that

• The runners cross section is circular

• the length and diameter of runners BE, CF and DG are same ( 2 inch and 3/16 inch respectively)

• The three runners are located at Equi-distance from each other (4 inch).

• The runners BE’, CF’ and DG’ are symmetrical to runners BE, CF, and DG.

8
The short shots are formed as a result of non-uniform filling of all the six cavities at the same time. In

order to fill all cavities at the same rate, it is required that the pressure drop across the runner and

cavity should be same. Since AB is a common path to all the cavities, the hydrodynamic condition to

achieve same pressure drop is;

∆𝑃𝐵𝐸 = ∆𝑃𝐵𝐶𝐹 = ∆𝑃𝐵𝐷𝐺 (a)

To begin with let us consider

∆𝑃𝐵𝐸 = ∆𝑃𝐵𝐶𝐹 (b)

∆𝑃𝐵𝐶𝐹 is equal to ∆𝑃𝐵𝐶 + ∆𝑃𝐶𝐹

i,e. ∆𝑃𝐵𝐸 = ∆𝑃𝐵𝐶 + ∆𝑃𝐶𝐹 (c)

If Q is the total volumetric flow rate at AB, then the flow rate through each of 6 runners should be

Q/6.

𝑄
i.e. 𝑄𝐵𝐸 = = 𝑄𝐶𝐹 = 𝑄𝐷𝐺 (d)
6

Material balance:

𝑄 2
𝑄𝐵𝐶 = 𝑄 − (2 × 6 ) = (3) 𝑄 (e)

For a power law fluid

τ = Kγ̇ n (f)

For a power law fluid flowing through a round tube, we have

τ = (∆P R)/2L (g)

3n+1 4Q
γ̇ = [ ] [ π R3 ] (h)
4n

therefore

9
Δ𝑃 𝑅 3n+1 4Q n
=K[[ ] [ π R3 ] ]
2𝐿 4n

or

2𝐾𝐿 3𝑛+1 4𝑄
Δ𝑃 = 𝐾 ( ) (i)
𝑅 4𝑛 𝜋𝑅 3

Using the relation shown in eqn (i), we can rewrite eqn (c) as

∆𝑃𝐵𝐸 = ∆𝑃𝐵𝐶 + ∆𝑃𝐶𝐹

𝑛 𝑛 𝑛
𝑄 2 𝑄
2𝐾𝐿𝐵𝐸 3𝑛+1 4( ) 2𝐾𝐿𝐵𝐶 3𝑛+1 4×( )𝑄 2𝐾𝐿𝐶𝐹 3𝑛+1 4( )
6 3 6
𝐾 ( ×( 3 )) = 𝐾 ( × ( 3 )) + 𝐾 ( ×( 3 ))
𝑅𝐵𝐸 4𝑛 𝜋𝑅𝐵𝐸 𝑅𝐵𝐶 4𝑛 𝜋𝑅𝐵𝐶 𝑅𝐶𝐹 4𝑛 𝜋𝑅𝐶𝐹

(j)

3𝑛+1 𝑛 𝑄 𝑛
By dividing eqn (j) by ( 4𝑛 𝜋 ) × 2𝐾 ( 6 ) we get

𝐿𝐵𝐸 𝐿𝐵𝐶 𝐿𝐶𝐹

3𝑛+1 = 3𝑛+1 4𝑛 + 3𝑛+1 (k)
𝑅𝐵𝐸 𝑅𝐵𝐶 𝑅𝐶𝐹

For n=0.5, eqn (k) becomes

𝐿𝐵𝐸 𝐿 𝑛 𝐿𝐶𝐹
2.5 = 𝑅𝐵𝐶
2.5 4 + 2.5 (l)
𝑅𝐵𝐸 𝐵𝐶 𝑅𝐶𝐹

for the given dimensions

𝐿𝐵𝐸 2
2.5 = 2.5 = 131.38
𝑅𝐵𝐸 (3⁄16)

𝐿𝐵𝐶 4
2.5 4𝑛 = 1 2.5 4
0.5
= 256
𝑅𝐵𝐶 ( ⁄4)

𝐿𝐶𝐹 2
2.5 = 2.5 = 131.38
𝑅𝐶𝐹 (3⁄16)

Note that

10
131.38 ≠256+131.38

Hence there is no unique solution for eq (l). Let us introduce some arbitrary constraint;

1. chose RCF a specific value and obtain a solution for RBE

2. Other dimensions can be retained

Let RCF = 0.1 inch (instead of given value of RCF is 3/16=0.1875 inch). Retain other values except

that of RBE. Then eq (l) becomes

2 2
2.5 = 256 +
𝑅𝐵𝐸 0.12.5

By solving for RBE, we get RBE=0.0873 inch (note that the original RBE=3/16 inch = 0.1875 inch).

Similar procedure was followed to estimate the value of RDG which is found to be 0.123 inch.

Comparison of the existing and proposed design.

Radius of old dimension, new dimension,

runner inch inch

RCF 3/16 (=0.1875) 0.1000

RBE 3/16 (=0.1875) 0.0873
RDG 3/16 (=0.1875) 0.1230

Since RCF ≈ RBE, the runners are thermally balanced as well.

-------------------------------------------------------------------------------------------------------------------------

11