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Numerical Investigation of Die Swell Behavior in EPDM Rubber Extrusion: Effects of Compound Formulation and Processing Conditions.

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Title: Numerical Investigation of Die Swell Behavior in EPDM Rubber Extrusion: Effects of Compound Formulation and Processing Conditions.
Authors: Sun, Yancai1,2,3,4 (AUTHOR), Wang, Haoran2,5 (AUTHOR), Jiang, Jingtao3,6 (AUTHOR), Wang, Kongshuo4,7 (AUTHOR), Bai, Wenjuan1,5 (AUTHOR), Chu, Dianming1,4,6 (AUTHOR), Jian, Ranran1,7 (AUTHOR), Hou, Peiwu1,8 (AUTHOR), He, Yan1,8 (AUTHOR) heyan@qust.edu.cn, Deng, Wenzhong2,3 (AUTHOR)
Source: Polymers (20734360). May2026, Vol. 18 Issue 9, p1122. 22p.
Subjects: Extrusion process, Viscoelasticity, Rubber chemistry, Ethylene-propylene rubber, Applied sciences
Abstract: Die swell is the dominant source of dimensional deviation in rubber profile extrusion. Because it is driven by recoverable elastic strain, a purely viscous baseline flow field cannot reproduce its speed dependence; a viscoelastic correction is required. This study presents, to the best of our knowledge, the first controlled comparison of a Carreau–Arrhenius baseline flow field against a fractional-order viscoelastic correction for carbon-black-filled EPDM across an industrial speed window. The viscoelastic correction (PyCFD-FMM) is a post-processing fractional-order viscoelastic swell correction built on the shared non-isothermal Polyflow Carreau–Arrhenius flow field, derived from a six-mode fractional Maxwell model parameterized from dynamic mechanical analysis via the Laun rule and closed through the Tanner recoverable-strain theory. Three carbon-black-filled EPDM compounds (Shore A 60–80) were extruded at four screw speeds (15–30 rpm) under instrumented conditions. Experimentally, swell ratios of 1.12–1.15 increase monotonically with screw speed (Fisher-combined p = 0.007 ; measurement repeatability CV ≤ 0.27 % across n = 4 replicates per condition). The purely viscous baseline output gives a decreasing apparent swell–speed trend—opposite to experiment—whereas PyCFD-FMM recovers the correct increasing trend for all compounds. Under single-anchor hold-out evaluation at 20/25/30 rpm, the non-anchor MAPE decreases from 0.99% for the baseline flow-field output to 0.30% (PyCFD-FMM); an anchor-sensitivity check over all four rpm choices keeps the compound-averaged non-anchor MAPE within 0.27–0.39% and preserves the correct slope sign in every case. Swell decomposition into geometric baseline and net correction factor ( B PyCFD = B geom × f corr ) confirms that the viscous baseline flow field captures flow-geometry effects but carries no elastic memory. Within the tested window, the viscoelastic correction meets a dual-gate criterion—correct slope sign and reduced non-anchor MAPE—which the purely viscous baseline cannot satisfy by construction. [ABSTRACT FROM AUTHOR]
Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Label: Title
  Group: Ti
  Data: Numerical Investigation of Die Swell Behavior in EPDM Rubber Extrusion: Effects of Compound Formulation and Processing Conditions.
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  Data: <searchLink fieldCode="JN" term="%22Polymers+%2820734360%29%22">Polymers (20734360)</searchLink>. May2026, Vol. 18 Issue 9, p1122. 22p.
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  Data: <searchLink fieldCode="DE" term="%22Extrusion+process%22">Extrusion process</searchLink><br /><searchLink fieldCode="DE" term="%22Viscoelasticity%22">Viscoelasticity</searchLink><br /><searchLink fieldCode="DE" term="%22Rubber+chemistry%22">Rubber chemistry</searchLink><br /><searchLink fieldCode="DE" term="%22Ethylene-propylene+rubber%22">Ethylene-propylene rubber</searchLink><br /><searchLink fieldCode="DE" term="%22Applied+sciences%22">Applied sciences</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Die swell is the dominant source of dimensional deviation in rubber profile extrusion. Because it is driven by recoverable elastic strain, a purely viscous baseline flow field cannot reproduce its speed dependence; a viscoelastic correction is required. This study presents, to the best of our knowledge, the first controlled comparison of a Carreau–Arrhenius baseline flow field against a fractional-order viscoelastic correction for carbon-black-filled EPDM across an industrial speed window. The viscoelastic correction (PyCFD-FMM) is a post-processing fractional-order viscoelastic swell correction built on the shared non-isothermal Polyflow Carreau–Arrhenius flow field, derived from a six-mode fractional Maxwell model parameterized from dynamic mechanical analysis via the Laun rule and closed through the Tanner recoverable-strain theory. Three carbon-black-filled EPDM compounds (Shore A 60–80) were extruded at four screw speeds (15–30 rpm) under instrumented conditions. Experimentally, swell ratios of 1.12–1.15 increase monotonically with screw speed (Fisher-combined p = 0.007 ; measurement repeatability CV ≤ 0.27 % across n = 4 replicates per condition). The purely viscous baseline output gives a decreasing apparent swell–speed trend—opposite to experiment—whereas PyCFD-FMM recovers the correct increasing trend for all compounds. Under single-anchor hold-out evaluation at 20/25/30 rpm, the non-anchor MAPE decreases from 0.99% for the baseline flow-field output to 0.30% (PyCFD-FMM); an anchor-sensitivity check over all four rpm choices keeps the compound-averaged non-anchor MAPE within 0.27–0.39% and preserves the correct slope sign in every case. Swell decomposition into geometric baseline and net correction factor ( B PyCFD = B geom × f corr ) confirms that the viscous baseline flow field captures flow-geometry effects but carries no elastic memory. Within the tested window, the viscoelastic correction meets a dual-gate criterion—correct slope sign and reduced non-anchor MAPE—which the purely viscous baseline cannot satisfy by construction. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Polymers (20734360) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.3390/polym18091122
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 22
        StartPage: 1122
    Subjects:
      – SubjectFull: Extrusion process
        Type: general
      – SubjectFull: Viscoelasticity
        Type: general
      – SubjectFull: Rubber chemistry
        Type: general
      – SubjectFull: Ethylene-propylene rubber
        Type: general
      – SubjectFull: Applied sciences
        Type: general
    Titles:
      – TitleFull: Numerical Investigation of Die Swell Behavior in EPDM Rubber Extrusion: Effects of Compound Formulation and Processing Conditions.
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            NameFull: Sun, Yancai
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              M: 05
              Text: May2026
              Type: published
              Y: 2026
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