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Polymer film melt stretching exhibits a unique stress–strain behavior, featuring a stress plateau followed by a sudden increase with increasing the strain. This phenomenon poses a challenge to conventional melt-extension theories and methods. To address this, we derive a simplified flow theory according to the symmetric characteristics of thin melt-stretching, and propose a modified multi-mode Leonov model (m-Leonov) that accounts for molecular orientation effects, a crucial factor in accurately simulating the process. In order to improve the computational efficiency, an iterative algorithm was developed to decouple the interdependence between governing and constitutive equations. The computational results reveal that the viscoelastic nature of the film contributes to a delay in the transformation of stretching forces, leading to the observed stress plateau. Significantly, our m-Leonov model successfully predicts both the plateau and the subsequent abrupt increase in stress, across various temperatures and stretching rates. These simulations closely agree with experimental data, underlining the robustness of our approach. Our findings would enhance the understanding of rheological complexities in film stretching, offering potential applications in various materials and polymer processing.
Ma et al. (Mon,) studied this question.