Modeling Air Entrainment and Temperature Effects in Winding

Rolls of films and paper are routinely stored under varying conditions before being unwound into downstream operations. During storage, interlayer pressures can change relative to the pressures generated during winding. These changes can lead to problems such as film/paper blocking (increased interlayer pressure) and roll shifting/cinching (decreased interlayer pressure). To study the storage effect, a nonlinear wound roll stress model including air entrainment is first developed and applied to predict the in-roll stresses during film/paper winding. Thereafter, a thermal stress model is used to study the temperature effect on wound roll stresses. Key inputs to the models are the stack modulus, contact clearance, and air film reference clearance. A method is developed to measure these key model inputs. Results of a parametric study show that among the processing conditions, storage temperature and thermal expansion coefficients of the core and the film/paper are key factors that affect in-roll stresses during storage. Limitations of the models will also be discussed along with recommendations for future modeling development.