Meaning
Internal resistance of a molten polymer to shear flow governs pressure drops through runner channels and cavity geometries. Magnitude of melt viscosity determines the required injection velocity and hydraulic pressure needed to fill thin wall sections during processing. Resistance changes dynamically with shear rate, temperature, and molecular weight distribution, stabilizing only under constant shear and isothermal conditions.
Standard datasheets quote melt flow index values under static weights, which fail to reflect actual flow resistance experienced at high injection speeds inside the mold. Lowering flow resistance allows processors to fill long flow length parts without exceeding press pressure capabilities.
Shear Dependence
Polymer chains uncoil and align parallel to flow lines under high shear rates, causing flow resistance to drop precipitously inside narrow gates. High velocity injection takes advantage of this shear thinning behavior to fill complex geometries rapidly.
Thermal Sensitivity
Increasing melt temperature imparts thermal energy to polymer chains, expanding free volume and lowering resistance to flow. Excess heat accelerates thermal degradation, reducing molecular weight and permanently altering material mechanical properties.
Moldability Boundary
Excessive melt resistance causes short shots, high residual stresses and severe flash near gate locations. Molders optimize barrel temperatures and injection speed profiles to hold flow resistance within acceptable process windows.