Numerical investigation of heat and mass transfer of the Sisko fluid in a wire-coating process with variable fluid properties

Abstract

Abstract The fundamental and essential objective of the wire coating process is to reduce the shear stress and extraction force exerted on the wire from the die in order to achieve practical benefits. Therefore, the purpose of the present work is to develop a mathematical model for the wire coating process withdrawal of the wire from the die. The Sisko fluid model and the temperature-dependent thermophysical properties are taken into consideration for modelling the constitutive equation. The basic equations governing the flow are solved with the aid of the numerical method. The impact of key factors is scrutinized. The influence of shear stress on the surface of the wire and fluid flow rate are delineated. The linear regression model is formulated to explore the significance of the relationship between the amount of force required to pull the wire and flow control variables. Moreover, the heat transfer rate and shear stress rate of molten polymer are modeled using quadratic correlation models obtained through the Central Composite Design (CCD) technique. To simultaneously achieve maximum heat transfer rate and minimum shear stress rate for the melt, the ideal values of the variable viscosity parameter, Sisko fluid parameter, and Brinkman number are determined. The study reveals that the required result occurs for a low level of the variable viscosity parameter, Sisko fluid parameter, and the Brinkman number. Additionally, a sensitivity analysis has been performed. The result reveals that the shear stress rate and heat transfer rate exhibit the highest sensitivity to variations in the viscosity parameter.