Improving the Quality of Web Material Production Through a Higher-Order Stress and Stability Model

本研究项目的目的是更好地了解金属、纸张和聚合物材料在制造并缠绕成大卷筒或线圈时所产生的应力和缺陷。该研究方法有两个任务：建立卷绕辊内应力状态的高阶数学模型，并进行实验室实验，以测量应力和出现v-屈曲、下垂崩溃和星形等失效模式的条件。这项研究专门针对非线性材料特性、辊径向和宽度方向的应力变化、粘弹性、层与层间摩擦损失引起的滑移，以及诸如张力调度和包装辊的设计等工艺改进。如果成功，该研究项目的结果将改善金属、纸张和聚合物材料的宽连续薄板的生产，这些材料有时被称为“网”。由于高缠绕张力和复杂的材料特性，缠绕辊可能会变得不稳定、屈曲，甚至完全崩溃。这项研究将促进与卷筒纸材料和轧辊的本构特性相关的知识。将确定驱动卷绕辊缺陷形成的干扰的关键来源。这项工作的潜在应用可能包括制造饮料容器中使用的铝板材，以及生产用于计算机数据墨盒的聚合物基膜。工业从业者可能能够将这些发现应用于卷筒纸材料，以将对底层辊的损害降至最低，降低废品率，并提高他们的产品质量。

The objective of this research project is to develop an improved understanding of the stresses and defects that occur when metal, paper, and polymer materials are manufactured and wound into large rolls or coils. The research approach has two tasks: developing a higher-order mathematical model for the state of stress within a wound roll, and conducting laboratory experiments to measure stresses and conditions for the onset of such failure modes as v-buckling, sag collapse, and starring. The research specifically addresses non-linear material characteristics, stress variations in the roll's radial and width-wise directions, viscoelastic properties, slippage due to loss of layer-to-layer friction, and such process improvements as tension scheduling and the design of packing rollers.If successful, the results of this research project will improve the production of wide continuous sheets of metal, paper, and polymer materials, which are sometimes referred to as "webs." Because of high winding tension and complex material characteristics, wound rolls can become unstable, buckle, or even collapse entirely. The research will advance knowledge relating to the constitutive characteristics of web materials and rolls. The key sources of disturbances that drive the formation of defects in wound rolls will be identified. Potential applications of the work may include the manufacture of aluminum sheet stock used in beverage containers, and the production of polymer base films that are used in computer data cartridges. Industrial practitioners may be able to apply the findings to wind web materials in a manner that minimizes damage to the underlying roll, that decreases scrap rates, and that improves the quality of their product.