Calendering

Mike Coster
James Coffey
Carly Snyder
The Machine
Typical Calender Line
Calender Roll Arrangements

I F

Z
Problems with Rollers
Newtonian Model
 Assumptions
 Newtonian flow
 Very small gap-to-radius ratio
 Lubrication approximation, only velocity components
 Large bank of melt in feed side
 Uniform velocity at outlet, no shear stress
 Advantages
 Compute flow rate per unit width
 Maximum pressure, shear strain, shear stress
 Power to drive system
 Roll separating force
 Rise in temperature
 Disadvantages
 Inaccurate for values less than ξ = -λ
 Newtonian Model vs.
Experimental Data

Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer Processing - Modeling and Simulation. 1st ed. Cincinnati, OH: Hanser Publishers, 2006.
 Roller Schematic

Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer Processing - Modeling and Simulation. 1st ed. Cincinnati, OH: Hanser Publishers, 2006.
 Newtonian Model
Equations Maximum Shear Stress:
Speed on roll surface:

n = revolutions per second, R = radius of roll

Flow rate per unit width: Power to drive system:

h = gap height, µ=velocity component, p= pressure, x

= position on x-axis of roll
W = gap width, ξ = dimensionless x-direction
Maximum pressure:
Roll Separating Force:

h0 = half the gap height

Maximum Shear Strain: Rise in Temperature:

η = height to roll from half gap height for given x-axis Q = heat transfer, Cp = constant pressure heat
position capacity
Shear Thinning Model

 Assumptions
 Lubrication approximation, only velocity
components
 Large bank of melt in feed side
 Advantages
 Correlates very well with experimental
values (max pressure)
 Can compute the pressure gradient, roll
separating force, and power required to
drive system
 Shear Thinning Model vs.
Experimental Data

Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer Processing - Modeling and Simulation. 1st ed. Cincinnati, OH: Hanser Publishers, 2006.
 Shear Thinning Model-
Shear Stress: Equations
m = consistency index, n = power law index

Pressure Gradient:

Power law dimensionless

pressure

Roll Separating Force:

Power to drive system:

Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer
Processing - Modeling and Simulation. 1st ed. Cincinnati, OH:
Hanser Publishers, 2006.
 Finite Sheet Thickness
 Previous had large mass Power law dimensionless
of polymer melt fed pressure:
 A finite polymer sheet of
thickness hf is fed
R = roll radius, h = half the spacing between the rollers ,
 Mathematical conform 0
P(n) = rolling pressure as a function of power law index n
well with experimental
data for both Newtonian The position where the sheet
and shear thinning being fed enters the system:
polymers.
hf = initial finite sheet thickness

Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer Processing - Modeling and Simulation. 1st ed. Cincinnati, OH: Hanser Publishers, 2006.
Calendering Sheet Defects
 Dimensional Non-uniformities
 Thickness variations in the sheets due to roll bending with large separation
forces. Compensated with crowned rolls – larger diameter in center than at
ends.
 Structural Anomalies
 Particulate and crystalline structure changes under the influence of high
temperature and stress
 Mattness
 Micro-irregularity or loss of surface gloss on the surface not in contact with the
roll when leaving the calender gap. Onsets at a wall shear stress value of
5x108 Pa.
 V-shapes
 Surface thickness variations with vertex of v-shape at center of sheet. Due to
undulating motions in the melt bank from the center to edges.
 Air Bubbles
 Captured in the melt bank. Can be prevented from passing through the
calender rolls through high pressure.
Uses

 Major plastic material

is PVC
 Also produced are:
 Wall coverings
 Upholstery fabrics
 Reservoir linings
 Agricultural mulching
materials
 Rubber sheet
http://www.allproducts.com/machine/shinekon/02.jpg
Rubber
 Made by a combination of extrusion and
calendering
 “roller die process”
 Better quality products than single process

©2002 John Wiley & Sons, Inc. M. P. Groover. “Fundamentals of Modern Manufacturing 2/e”
Coating and Impregnating
Fabrics
 Industrial process
used to produce:
 Car tires
 Conveyer belts
 Inflatable rafts
 Waterproof cloth
tents
 Rain coats

©2002 John Wiley & Sons, Inc. M. P. Groover. “Fundamentals of Modern Manufacturing 2/e”
Limitations

 Thickness
 Generate film or sheet with a uniform
thickness distribution
 Precise dimensions of the rolls
 Cost
 Installation requires large capital investment
 Extruder is fraction of cost of calender
 Superior for product production due to high
quality and volume capabilities
References
 Osswald, Tim A., and Juan P. Hernández-Ortiz. Polymer
Processing - Modeling and Simulation. 1st ed. Cincinnati, OH:
Hanser Publishers, 2006.
 Vlachopoulos, J., and E. Mitsoulis. "Fluid Flow and Heat Transfer
in Calendering." McMaster University, Department of Chemical
Engineering.
©2002 John Wiley & Sons, Inc. M. P. Groover. “Fundamentals of
Modern Manufacturing 2/e”