Gravure printing with a shear-rate-dependent ink

Gravure printing is a type of printing method that uses metal cylinders with engraved cells that hold ink. The ink is transferred directly to the paper or other material by pressing it against the cylinder. The flow associated with gravure printing includes a flow in a liquid bridge formed in the contact region of the cylinders and a thin-film coating flow of the ink. The flow is governed by viscous and capillary forces. In many cases, the flow is unstable, which leads to the formation of instability patterns on the printed surfaces. The analysis of these instabilities is a very challenging problem, especially since industrial inks are usually rheologically complex. In this experimental and theoretical study, the flow of inks on a rotating cylinder is analysed, accounting for the shear-rate-dependent liquid viscosity. A theoretical solution for the film flow allows us to predict the width of the liquid bridge between two cylinders. Moreover, it is shown that the measured characteristic size of the printed pattern is of the same order as the predicted liquid bridge width. We observe a nearly linear dependence of pattern size and liquid bridge width.