Numerical simulation for viscous free‐surface flows for reverse roller‐coating Available to Purchase

This article is concerned with the numerical simulation of a reverse roller‐coating process, which involves the computation of Newtonian viscous incompressible flows with free‐surfaces. A numerical scheme is applied of a transient finite element form, a semi‐implicit Taylor‐Galerkin/pressurecorrection algorithm. For free‐surface prediction, we use kinematic boundary adjustment with a mesh‐stretching algorithm. In the present work, an alloy sheet (foil) passes over a large roller and then a smaller applicator roller, which provides the in‐feed. In combination, the applicator roller, the foil and the fluid form part of the underside coating mechanism. The aim of this study is to investigate fundamental aspects of the process, to ultimately address typical coating instabilities. These may take the form of chatter and starvation. A uniform coating thickness is the desired objective. A mathematical model is derived to describe the solvent coating applied to the underside of the sheet, assuming that the lacquer is a Newtonian fluid. In particular, the work has concentrated on the flow patterns that result and a parameter sensitivity analysis covering the appropriate operating windows of applied conditions. Effects of independent variation in roll‐speed and foil‐speed are investigated, to find that maxima in pressure, lift and drag arise at the nip and are influenced in a linear fashion.