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Hashimoto
Professor,
Dean of Graduate School of Engineering
e-mail: hiromu@keyaki.cc.u-tokai.ac.jp
M. Okajima
Graduate Student
Tokai University,
1117 Kitakaname, Hiratsuka-shi,
Kanagawa-ken 259-1292, Japan
Introduction
Continuous flexible thin materials such as paper, textiles, filters,
plastic films, and thin metal plates are sometimes called webs.
Web transport systems are very important in manufacturing such
materials. Moving webs and rotating rollers bring the surrounding
air between a web and a roller due to the viscosity of the air and
the web-roller interface behaves as a self-acting foil bearing. As a
result, the entrained air forms what is called soft elastohydrodynamic lubrication EHL air film inside the gap and causes a
decrease of traction between the web and the roller. If the air film
thickness is increased to a level greater than the combined asperity
heights of the web and the roller surfaces, the available traction is
due only to the fluid film friction which is equivalent to zero
friction. In the case of an idler roller driven by the web, insufficient traction results in a lower speed of the roller than the web
and then reduces the tracking ability of the web which subsequently causes web defects. As this decrease in traction is a direct
result of air entrainment between the web and the roller, it is
important to predict the air film thickness accurately for controlling the traction in many web handling applications.
The first step in modeling the web-roller interface problems
requires a numerical model for estimating the air film thickness
between the web and the roller. This problem is similar to tapehead interface problems in magnetic storage systems. A number of
published papers related to tape-head interface problems are available in the literature. When the tape width is much larger than the
tape length wrapped over the head, the tape has been assumed to
be infinitely wide. Under such an assumption, Block and van Rossum 1 and Eshel and Elrod 2 solved the incompressible Reynolds equation combined with the foil equilibrium equation and
presented a closed-form formula for estimating the air film thickness. The direct numerical calculation of a one-dimensional tapehead interface model has been presented by Stahl et al. 3, and
Granzow and Lebeck 4. The results by these authors are essenContributed by the Tribology Division of ASME for publication in the JOURNAL OF
TRIBOLOGY. Manuscript received February 25, 2004; final manuscript received
October 6, 2005. Review conducted by Michel Fillon.
Journal of Tribology
tially the same as the results by Eshel and Elrod. On the other
hand, Ono et al. 5, Moes 6, Muftu and Benson 7, and
Lakshmikumaran and Wickert 8 employed two-dimensional
analyses which consider the effect of tape width. The main aims
of these papers are to improve the convergence of the numerical
solutions, and as far as the authors know, there has been no attempt to derive a closed-form formula for estimating the air film
thickness based on a two-dimensional foil bearing model.
In modeling web-roller interface problems, the effect of web
width is important because the web width can vary from very
narrow to very wide in the actual applications. In addition to the
finite width effect, the air diffusion due to web permeability has a
significant effect on the air film thickness in the case of permeable
webs such as paper, textile and filters. References related to the
numerical modeling of the air film thickness which include the
effects of both web width and permeability are very limited.
Ducotey and Good 9 derived a closed formula for predicting the
air film thickness based on one-dimensional foil bearing model
considering the effect of web permeability, web width, wrap
angle, and side leakage. Muftu and Altan 10 presented a model
for analyzing the interfacial conditions of a porous web moving
over a cylindrical rigid guide, in which the porous web is modeled
as a moving cylindrically curved beam, and the solid-body contact
between the web and the guide is modeled using an asperity compliance function.
In this paper, a new theoretical model for estimating the entrained air film thickness between the web and the roller is presented for both impermeable and permeable webs. A simple
closed-form formula for predicting the air film thickness is suggested, which includes the effects of both air leakage from web
edges and air diffusion due to permeability. The predicted results
of air film thickness are compared with the measured data, and the
validity of the model is experimentally verified.
Theoretical Modeling
Figure 1 shows an example of a web transport system, in which
the moving web is supported by several kinds of rollers. In such
transport systems, it is very important to understand the spacing
d=
1
RB
x+
2R
2
0
RB
RB
x
2
2
1
RB
x
2R
2
RB
2
RB
2
pxs,z = pa,
and friction characteristics between the web and the roller. The
web-roller interface problem is similar to the tape-head interface
problem and the self-acting foil bearing model as shown in Fig. 2
may be applicable to theoretically treat problem. Thus, the closedform formula for estimating the air film thickness will be derived
for the impermeable web in the first step.
The air film pressure generated in the gap between the web and
the roller is given by the following compressible Reynolds equation 11,12:
ph
3 p
3 p
h p
+
h p
= 6U
x
z
x
x
z
2w 1
T
T 2 =
x
R
L
wxs = 0,
2w
x2
5b
wxe = 0
2w
x2
= 0,
x=xs
h =
h
,
R2/3
p =
B
,
1/3
p pa
,
T/R
=
w
d
,
R3/2
6a
6b
=0
x=xe
w
,
R2/3
x =
L
,
2R1/3
x
z
, z =
R1/3
L
=
6U
T
7
3 p
ph
1 3 p
h p
+ 2
h p
=6
4 z
x
z
x
x
2w
=
x2
The relation between air film thickness and web deflection is expressed by the following equation:
pdz
0.5
10
x +
2
2
x
2
2
px
s,z
= 0,
px
, 0.5 = 0,
x
s = 0,
w
2w
x2
= 0,
x=x
s
0.5
h = w
+
L
= pa
2
where xs and xe indicate the coordinates of inlet and outlet boundaries of web-roller interface, and these are the unknown variables.
In the numerical analysis of air film thickness and pressure
distributions, the following normalized quantities are used:
L/2
h=w+d
p x,
L/2
p padz
L
= p a,
2
p x,
5a
pxe,z = pa
x
2
2
x
2
px
e,z
= 0
12a
px
,0.5 = 0
x
e = 0
w
2w
x2
11
12b
13a
=0
13b
x=x
e
Equations 8 through 10 were discritized by the finite difference method and solved simultaneously by applying the NewtonRaphson iterative scheme subject to the boundary conditions 12
and 13a until the convergence condition was satisfied, and the
nondimensional air film thickness and pressure distributions were
obtained. The unknown values of xs and xe were determined itera-
Fig. 5 Numerical solution of nondimensional air film thickness valid for > 6
Typical numerical results of air film thickness and pressure distributions are shown in Fig. 4 for the normalized wrap angle of
= 9.0, in which the parameter is used to show the effect of web
width. As has been already pointed out by Eshel and Elrod 2, as
the amount of air leakage from both edges of web decreases with
an increase of , the air film thickness increases and becomes
constant in the direction of web travel. The pressure spike and the
local contraction of air film thickness distribution near the outlet
boundary of web-roller interface can be seen in these results. The
numerical calculations were carried out by changing the value of
normalized wrap angle . It was found that an increase in the
wrap angle lengthens the central part of air film thickness distribution where the air film pressure is nearly constant, while the
inlet and outlet regions remain the same shapes in the case of
6.
The normalized air film thickness distribution at the center of
= 0 is shown in Fig. 5 for various values of parameter .
web z
As can be seen in the figure, the numerical solutions converge to
the solutions of infinitely wide web at the inlet and outlet of the
web wrapped region and the solutions take minimum values near
/ 2. For 7, the air
the outlet of the web wrapped region x
film thickness becomes constant in the central region of wrap
angle over 90% of web-roller interface. Considering these char-
Fig. 4 Numerical results of nondimensional pressure distribution and air film thickness for = 9.0
Journal of Tribology
acteristics of numerical solutions, a closed-form formula for predicting the air film thickness can be derived as explained below.
The plots in Fig. 6 show the variation of normalized air film
= 0 and z
thickness at the central point of the wrapped region x
= 0 with the parameter . Applying the least mean square method
to the numerical results, indicated by the plots, the following
approximate relation between the normalized air film thickness h0
and the parameter is obtained:
h0
1.614 1.764
h0
= 0.589
+
R2/3
14
Using this relation which accounts for the considerable decrease in the air film thickness from the solution for the infinitely
wide web h0 = 0.589, and assuming that the air film thickness
decreases linearly at the inlet region and become constant at the
central region which occupies the major region of wrap angle, the
closed form formula for predicting the air film thickness distribution between the web and roller surfaces is obtained as follows:
hx = R2/30.589 + fgx
15
gx =
aRB/2 x RB/2
16
17
18
tp
where the pressure difference p and the time required for a specific air volume to flow through a given area under a certain
pressure difference t are given approximately as follows:
t f
T
,
R
2x + RB/2
U
19
k TB
t f U
1+
2x
RB
20
The air film thickness for permeable web is obtained by subtracting the film thickness due to permeability from the air film
thickness for a finite width web 13
h = h h
=R2/30.589 + fgx R1 + 2x/RB
for h 0
21a
and
h=0
for h 0
21b
kTB
t f RU
22
It follows from Eqs. 21a and 22 that the air film thickness h
decreases with an increase of web permeability k, web tension T,
or wrap angle B, and decreases with a decrease of web thickness
t f and velocity U.
270 / Vol. 128, APRIL 2006
Specification
Material of roller
Roller radius R m
Roller velocity Ur m/s
Web width L m
Tension T N/m
Web wrap angle B deg
RMS roughness of roller Rrq m
Maximum roughness height of roller Rr
max
SCM440
0.055
013.0
0.035
80
60
0.751
3.87
tf
t
23
Journal of Tribology
Fig. 11
Results for PET are shown in Fig. 10b. Since the roller radius
used in the measurements was about nine times the radius in the
measurements for coated paper, the air film thickness is much
larger than the thickness for the coated paper measured by the
authors. As PET is impermeable as mentioned previously, the air
film thickness is constant in the circumferential direction in the
wide range of web wrapped region. There is good agreement between the measured results and the results predicted from Eq. 21
in the case of velocity range of Ur 5.08 m / s but the error becomes larger for a roller velocity of 7.62 m / s. In the figure, the
results calculated by Ducoty and Good 13 are also indicated. In
their calculation, the squeeze film model is employed for accounting for the air leakage effects. Although the Ducoty and Good
model overestimates the experimental results, an amount of overestimation becomes smaller with an increase of web velocity.
Results for newsprint are shown in Fig. 10c. In this case, it is
difficult to increase the air film thickness due to the large permeability of web. The web starts to float at the roller velocity of
Ur = 12.7 m / s. The air film thickness linearly decreases in the circumferential direction and the web is in contact with roller near
the outlet of web wrapped region. This may be due to the apparent
increase of web tension as Ducotey and Good state in their paper
13. The calculated results predict the experimental results qualitatively but not quantitatively, especially in the cases of low velocities.
The variation of the air film thickness at the center of web x
= 0 and z = 0 in Fig. 2 with roller velocity is shown in Figs. 11
Journal of Tribology
show the results neglecting the effect. The web cannot become
airborne due to large permeability for a wide range of roller velocity and the air film thickness between the web and the roller is
less than the composite rms roughness of the web and roller surfaces 3 4 m in both cases of L = 0.012 m and L = 0.035 m.
Based on the results, it appears that the web is actually in contact
with roller surface. The air film thickness predicted from Eq. 21
remains zero for the full range of velocities considered in the
experiments but the measured air film thickness slightly increases
with an increase of velocity. However, the air film thickness is still
less than the maximum surface roughness height in both predicted
results and measured results.
From the results presented in Figs. 10 to 13, there is good
agreement quantitatively and qualitatively between the results predicted from Eq. 21 and the measured results. It is recommended
that Eq. 21 be used for the first-order estimation of air film
thickness.
Conclusions
In this paper, a simple curve fit formula for predicting the entrained air film thickness between the web and the roller was
obtained, which considers the effects of side leakage and air diffusion due to web permeability. The results of air film thickness
predicted from this formula were compared with the measured
results for three types of webs with different permeabilities, including PET, coated paper, and uncoated paper newsprint. The
main conclusions are briefly summarized as follows:
1 The air film thickness predicted from Eq. 21 agree
well with the measured results qualitatively for various
combinations of web width, tension, roller radius, and
web permeability for a wide range of roller velocity.
2 The air film thicknesses predicted from Eq. 21 agree
with the measured results quantitatively for a impermeable web PET within an acceptable error less than 5%
except large velocities where Ur 10 m / s.
3 The air film thickness predicted from Eq. 21 underestimates the measured results for a low permeability web
coated paper within 15% error except in a low velocity
region of Ur 3 m / s.
4 A high permeability web newsprint is difficult to float
due to air diffusion through web surface for a full range
of velocities considered in the experiments. The air film
thickness was zero in both cases of the results predicted
from Eq. 21 and the measured results.
Nomenclature
A
a
B
E1
E2
f
gx
h
h0
h
h
k
Rr max
Rrqrms
Rw max
Rwqrms
T
t
L
p
pa
p
p
Q
R
tf
U
Ur
Uw
w
x
xs
xe
x
z
z
web width m
air film pressure Pa
ambient pressure Pa
normalized air film pressure p pa / T / R
pressure difference Pa
volumetric air flow rate m3 / s
roller radius m
maximum roughness of roller surface m
rms roughness of roller surface m
maximum roughness of web surface m
rms roughness of web surface m
web tension N/m
time required for a specified air volume to
flow though a given area under a certain pressure difference s
web thickness m
transport velocity Ur + Uw m/s
roller velocity m/s
web velocity m/s
web deflection m
coordinate in the transporting direction m
inlet boundary in the web-roller interface m
outlet boundary in the web-roller interface m
normalized coordinate in the transporting direction x / R1/3
coordinate in the axial direction of roller m
normalized coordinate in the axial direction of
roller z / L
normalized web permeability
kTB / t f RU
normalized wrap angle B / 1/3
normalized shape function d / R2/3
web parameter 6U / L
normalized web width L / 2R1/3
air viscosity Pa.s
References
1 Block, H., and van Rossum, J. J., 1953, The Foil Bearings: A New Departure
in Hydrodynamic Lubrication, Lubr. Eng., 96, pp. 310320.
2 Eshel, A., and Elrod., H. G., 1965, The Theory of Infinitely Wide Perfectly
Flexible Self-Acting Foil Bearings, ASME J. Basic Eng., 87, pp. 831836.
3 Stahl, K. J., White, J. W., and Deckert, K. L., 1974, Dynamic Response of
Self Acting Foil Bearings, IBM J. Res. Dev., 186, pp. 513520.
4 Granzow, G. D., and Lebeck, A. O., 1984, An Improved One-Dimensional
Foil Bearing Solution, ASLE Spec. Publ., 16, pp. 5458.
5 Ono, K., Kodama, N., and Michimura, S., 1991, A New Numerical Analysis
Method for Two-Dimensional Foil Bearing Problems Based on Inverse Analysis Concept, JSME Int. J., Ser. III, 34, pp. 8290.
6 Moes, H., 1991, The Air Gap Between Tape and Drumina Video Recorder, J.
Magn. Magn. Mater., 95, pp. 113.
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Finite Width Tension Dominated Foil Bearings, ASME J. Tribol., 121, pp.
108113.
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ASME J. Tribol., 121, pp. 618624.
10 Muftu, S., and Altan, C. M., 2000, Mechanics of Porous Web Moving Over a
Cylindrical Guide, ASME J. Tribol., 122, pp. 418426.
11 Hashimoto, H., 1997, Effect of Foil Bending Rigidity on Spacing Height
Characteristics of Hydrostatic Porous Foil Bearings for Web Handling Processes, ASME J. Tribol., 123, pp. 509516.
12 Hashimoto, H., 1999, Air Film Thickness Estimation in Web Handling Processes, ASME J. Tribol., 121, pp. 5055.
13 Ducotey, K. S., and Good, J. K., 1998, The Effect of Web Permeability and
Side Leakage on the Air Film Height Between a Roller and Web, ASME J.
Tribol., 120, pp. 559565.