Simulation of Spinning Processes with Experimental Validation
Melt-spinning processes are important industrial processes with applications ranging from staple fibers and nonwovens to industrial fibers. Concerning the fiber properties and quality, the spinning process is a crucial step in the production chain. Especially the degree of crystallization influences the mechanical and chemical properties of the fibers. During the melt-spinning process, the molten polymer is pushed at high pressure through small holes, is drawn and quenched at high speeds with the simultaneous alignment of polymer chains and crystallization processes in the fiber. During this process, the fiber properties are determined and can be controlled via different parameter settings. Fraunhofer ITWM has developed suitable methods to simulate such a complex process. A weak iterative coupling algorithm based on the combination of commercial software and self-implemented code makes the simulation of the industrial spinning processes possible. Simulations results are validated by trials at the melt-spinning machine of AMIBM where we observe good agreement with experimentally measured data. Being able to adequately simulate the melt-spinning process offers great potential for instance to the polymer and material research departments. With small amounts of material and fundamental analysis of the thermal and physical properties, different fiber applications can be estimated and improved.