Influence of variable viscosity on existing sheet thickness in the calendering of non-isothermal viscoelastic materials

The calendering process is pivotal in enhancing various materials’ surface properties and characteristics, making them indispensable for achieving desired product quality and performance. Also, this process holds significant relevance in various industrial applications, such as polymer processing, food production, and the manufacturing of composite materials. So, the aim of this study is to theoretically examine the calendering process applied to third-grade materials. It specifically explores how temperature variations impact material behavior during passage through two counter-rotating heated rolls. Particular consideration is given to the influence of temperature-dependent viscosity via Reynold’s model. The complexities of mass, momentum, and energy balance equations are reduced through the application of the Lubrication approximation theory. Solutions to these equations for variables such as velocity, flow rate, and temperature fields are accomplished by combining perturbation and numerical techniques. In relation to the calendering process, the thickness of the exiting sheet is specifically explored. Furthermore, this study quantifies substantial engineering parameters such as roll-separating force, pressure distribution, and power transferal from the rolls to the fluid. The governing equations belong to three key dimensionless parameters, namely, the Brinkman number, which is a product of Eckert number and Prandtl number, the temperature-dependent consistency index μ \mu , and a parameter η \eta correlating to non-Newtonian behavior. The outcomes of this study are presented both graphically and in tabular form. It has been observed that a rise in the third-grade parameter decreases detachment point and sheet thickness due to increased material rigidity. Furthermore, established results in the literature regarding the calendering of Newtonian fluids are validated.