Simultaneous Calculation of Roll Deformation and Polymer Flow in the Calendering Process

Abstract

Abstract Calender units with rotating rolls are used to produce foils or sheets from polymer material with viscous or elastomeric flow properties. Up to now, the design process of calender units, the calculation of flow and pressure fields in the calender gap and the calculation of resulting deformations of the rotating rolls are implemented with different computer programs. In this work a design concept that integrates design and calculation programs is being developed in order to achieve integrated design and calculation. With this concept, it is possible to design calenders and calculate flow fields and deformations. After designing the rolls with the Computer Aided Design program Pro/Engineer, the flow field in the calender gap is calculated with the Finite Volume Method program CFX4, and the deformation of the rolls is calculated with the Finite Element Method program ANSYS. The iterative process of design, calculation and modification of shape is continued until sheets or foils of constant thickness leave the calender gap. The design concept has an object-oriented operational structure. The data transfer between the programs takes place via a central data base in STEP format. As examples, calenders with combinations of solid rolls are designed. The flow field in the calender gap is calculated for Newtonian and for viscoelastic fluids with use of an integral rheological equation of state. The flow field is compared to a measured flow field. The resulting deformations of the rolls are calculated and represented graphically. Furthermore, a design process for elastomer-coated rolls is implemented and their deformations as well as the interior stress fields are calculated.