Shear-induced particle migration in a short-dwell coater

Numerical Modeling of a Short-Dwell Coater for Bio-Based Coating Applications

Computational fluid dynamics (CFD) simulations were used for the evaluation of critical issues associated with coating processes with the aim of developing and optimizing this important industrial technology. Four different models, namely, the constant viscosity, shear thinning, Oldroyd-B viscoelastic, and Giesekus models, were analyzed and compared in a short-dwell coater (SDC) using a bio-based coating material. The simulation results showed that the primary vortex formations predicted by the viscoelastic models were highly dependent on the flow Deborah number, resulting in uneven stress distribution over the coated surface. For the viscoelastic models, the dominance of elastic forces over viscous forces gave rise to significant normal stress difference, primarily along the surface of the substrate paper. The shear-thinning phenomena predicted by the Giesekus model, however, tended to relax the stress development in contrast to the Oldroyd-B model. The observations indicate that a reduced coating velocity or modification of the coating material with a reduced relaxation time constant can significantly enhance the uniformity and thickness of the coating over the coated surface under controlled conditions.

Shear-induced particle migration in one-, two-, and three-dimensional flows

We investigate the segregation resulting from the competition between advection and shear-induced migration of suspensions in steady open flows. Herringbone channels form a concentration profile deviating from the particle focusing found in straight channels. Transients can result from a buckling instability during the onset of migration when particle-depleted fluid is injected into particle-rich fluid. In chaotic flows, the better mixing found at low bulk volume fraction is not seen at higher bulk volume fraction. Thus, the ability of static mixers to reduce the effects of shear-induced migration is significantly limited.