A numerical analysis of calendering (Q1119080)

An analysis of calendering of inelastic (power-law) and viscoelastic sheets of finite initial thickness has been carried out using (i) a perturbation method based on lubrication theory; (ii) an approximate treatment including normal stress effects; (iii) a full numerical analysis using the boundary element method. The Phan-Thien-Tanner (PTT) fluid model was used in the viscoelastic analyses. Attention is focused on the separation criterion at the roll exit plane. While it is usual to assume in the inelastic case that separation occurs when the pressure and pressure gradient vanish simultaneously, it is not clear that this is approximate in the viscoelastic model. The main new results are (a) a method of determining the separation point numerically using the criterion of zero tangential traction; (b) a computation of welling (\(\sim 5\%)\) after the sheet leaves the nip; (c) a demonstration that the roll force first decreases a Weissenberg number (roll speed) rises, and then increases.