Aerodynamics and Heat Transfer in Polymer Blown Film Processing: Experimental and Numerical Investigation

Authors

Mohammad Luqman Zulbakri, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Nur Atiqah Mat. Rautin, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Raa Khimi Shuib, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Ku Marsilla Ku Ishak, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Auratus Zuratul Ain Abdul Hamid, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Mohamad Danial Shafiq, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Mohamad Yusof Idroas, School of Mechanical Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow
Muhammad Khalil Abdullah, School of Materials and Mineral Resources Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, MalaysiaFollow

Abstract

The effects of airflow dynamics, heat transfer, and mechanical properties on the HDPE blown film extrusion process were examined using a single-lip air ring with a fixed compressed-air valve opening angle of 10°. Reynolds numbers ranging from 9175 to 25911 were analyzed to understand their impact on cooling efficiency, bubble morphology, and film properties. Numerical simulations employing the Standard k−ω turbulence model in ANSYS FLUENT v2023, with mesh refinement achieving y+ ≈ 1, captured detailed flow and heat transfer behavior. Results showed that higher Reynolds numbers significantly enhanced the heat transfer coefficient, with values increasing from 1096 W/m²·K at Reynold number of 9175 to 1438 W/m²·K at Reynolds number of 25911, reducing the axial cooling distance by up to 30%. This rapid cooling improved the cooling rate but led to a reduced lay-flat width (from 29.10 cm at a Reynolds number of 9175 to 27.50 cm at a Reynolds number of 25911) and thicker films. The tensile stress decreased from 25.25 MPa at a Reynolds number of 9175 to 20.84 MPa at a Reynolds number of 25911, reflecting the impact of turbulence on the polymer chain alignment. These findings emphasize the trade-offs between enhanced cooling efficiency and material properties, offering critical insights for optimizing blown film extrusion processes for improved quality and operational performance.

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Recommended Citation

Zulbakri, Mohammad Luqman; Mat. Rautin, Nur Atiqah; Shuib, Raa Khimi; Ku Ishak, Ku Marsilla; Abdul Hamid, Auratus Zuratul Ain; Shafiq, Mohamad Danial; Idroas, Mohamad Yusof; and Abdullah, Muhammad Khalil (2025) "Aerodynamics and Heat Transfer in Polymer Blown Film Processing: Experimental and Numerical Investigation," Makara Journal of Technology: Vol. 29: Iss. 3, Article 3.
DOI: 10.7454/mst.v29i3.1721
Available at: https://scholarhub.ui.ac.id/mjt/vol29/iss3/3