Perturbation based analytical and numerical solutions of non-Newtonian differential equation during reverse roll coating process under lubrication approximation theory

Abstract

Abstract Reverse roll coating process are utilized for the purpose of applying a coating to a substrate or web by utilising different rollers in order to get the required coated surface. As a result of this, reverse roll coating process have found applications in a wide variety of industries, such as those dealing with food and medicine, electronic components, optical and LCD devices, and optical products. The main objective of this paper is to develop the mathematical formulation for the coating of thin film for an incompressible isothermal viscoelastic fluid between two reversely rotating rolls. Through the use of an appropriate dimensionless parameter, Non-dimensional nonlinear ordinary differential equations (ODEs) are derived from governing partial differential equations (PDEs). LAT (lubrication approximation theory) simplifies the dimensionless equations of fluid motion. The expressions for velocity of flow, pressure gradient and flow rate is obtained analytically by using regular perturbation method, while numeric solution of some mechanical parameters such as power input, coating thickness, roll separation force and separation points are calculated. The numerical validation of the analytical solution of the fundamental model of nonlinear constitutive flow laws is done in the Maple environment using the numeric technique which is based on finite difference method. The influence of numerous non-Newtonian parameters such as velocities ratio and Weissenberg number on velocity profiles, pressure gradient, power input, roll separation force, separation points and coating thickness of a non-Newtonian Johnson–Segalman (JS) fluid are explored via graphically and in tabular form. The outcomes demonstrate that on increasing the Weisenberg number and velocities ratio, the coating thickness on web is decreases. For the numerous values of velocities ratio, it is important to note that separation points shifted towards the nip region. In addition, the non-Newtonain parameter have signifcant impact on power input and roll separating force. The maximum coating thickness that is 1.0927 has been observed at the value of separation poin 0.9620. Hence, these factors may help in an efficient coating process and improve the substrate life.