Finite-element analyses of blade and slot coating flows using an implicit pseudo-solid domain mapping technique coupled with unstructured grids
In coating processes (e.g. in blade coating) the flow domain inherently contains free surfaces and three-phase contact lines, and characteristic length scales of flow features in the dimension transverse to the web-movement vary by an order of magnitude or more from a fraction of a millimeter or more to tens of microns or less). The presence of free surfaces and three-phase contact lines, and the sudden changes of flow geometry and directions create difficulties in theoretical analyses of such flows. Though simulations of coating flows via finite-element methods using structured grids have been reportedly demonstrated in the literature, achieving high efficiency of such numerical experiments remains a grand challenge -- mainly due to difficulties in local mesh-refinement and in avoiding unacceptably distorted grids. High efficiency of computing steady flow fields under various process conditions is crucial in shortening turn-around time in design and optimization of coating-flow processes. In this paper we employ a fully-implicit, pseudo-solid, domain mapping technique coupled with unstructured meshes to analyze blade and slot coating flows using Galerkin`s method with finite element basis functions. We demonstrate the robustness and efficiency of our unique technique in circumventing shortcomings of mesh-motion schemes currently being used in the coating-flow research community. Our goal is to develop an efficient numerical tool, together with a suitable optimization toolkit, that can be used routinely in design and optimization of coating-flow processes.
- Research Organization:
- Sandia National Labs., Albuquerque, NM (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC04-94AL85000
- OSTI ID:
- 26602
- Report Number(s):
- SAND--94-2965C; CONF-9505146--1; ON: DE95004774
- Country of Publication:
- United States
- Language:
- English
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