Numerical analysis of two-layered isothermal calendering of viscoplastic and Newtonian fluids with different viscosity ratios

Co-extruded multi-layer plastic sheets and polymer structures formed by calendering process or by cold rolling are widely used in the packaging industry and thin-film transistor manufacturing. The different materials are extruded from separate extruders into the single sheet die which delivers a multi-layer sheet with uniform layer thickness at die exit. This multi-layer sheet is then stretched between counter-rotating rolls to obtain final uniform multi-layer sheet. There are many factors which can influence this process. In this article, calendering a single layer Newtonian or Non-Newtonian material has been extended to analyze a two-layer calendering process for an incompressible Viscoplastic and Newtonian fluids as upper and lower layers with different viscosity ratios. To simplify the equations of motion, the lubrication approximation theory is used. The expressions of non-dimensional pressure gradient, pressure and velocity distribution of both layers are obtained analytically by using proper no slip boundary conditions and dimensionless variables. The dimensionless detachment point is approximated by Regula-Falsi (false position) method. The important engineering factors including detachment point, calendered sheet thickness, roll separation force, power input by rolls, torque on each roll, and adiabatic temperature are all computed. In addition, how the viscosity ratios and viscoplastic casson parameter affect these factors have been investigated. Moreover all established results in literature for single layer calendering Newtonian fluids are also validated at casson parameter β tending towards infinity.