Mathematical analysis of a non-Newtonian polymer in the forward roll coating process

This article describes the development of a mathematical model of forward roll coating of a thin film of a non-Newtonian material when it passes through a small gap between the two counter-rotating rolls. The conservation equations of mass, momentum, and energy in the light of LAT (lubrication approximation theory) are non-dimensionalized and solutions for the velocity profile, flow rate, pressure distribution, pressure, forces, stresses, power input to the roller, and temperature distribution are calculated analytically. It is found that by changing (increasing/decreasing) the value of material parameters, one can really control the engineering parameters like, stress and the most important the coating thickness and is a quick reference for the engineer working in coating industries. Some results are shown graphically. From the present study, it has been established that the material parameter is a device to control flow rate, coating thickness, separation points, and pressure distribution.