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PEER REVIEWED
DAVID R. ROISUM
WEB DEFECTS
////
(oMD=IO,T = 0)
^X
///s \
//A
(CJCD = -2.5,X = 0)
////
Element stress
Element stress
Web
No wrinkles
/. Pure MD tension
Web
Causes
Constrained expansion Roller
crown Roller deflection Bad
'spreading'
Causes
11
Ten
2
(1)
where
w
= width
u?1 = Poisson's ratio
Ten = lineal web line tension
E, = MD modulus
c
= caliper
a,
= CD coefficient of thermal
expansion
T
= temperature
62
= CD coefficient of solvent
expansion
4. MD trough wrinkle
bt.iL
Web travel
Misalignment
Tension profile
Draw profile
Material skew
Deflection
Net
Tension
Weight
3. MD tension + shear
where
X = wavelength
L = web span length
Ten = lineal web line tension
E = web modulus
oCj = longitudinal stress = Ten /caliper.
_ / TL4_\
" 2b " V % )
where
_,
ID
A
= amplitude A.
= wavelength.
WEB DEFECTS
Web
Web
Region I
Planar
Increase L/W
Region III
Wrinkled
Increase gauge
8. Misalignment wrinkle relationships
Shell
Groove
Wide grooving:
Web may slide
inward into
grooves
Shell
Thread
CD
LU
R
egion
6. Wrinkling at wide grooves/threads
Partial drive
II
Rivers & lakes
Slack
edge
b/l
MISALIGNMENT
ANGLE
-c
A
-c
>
-Ci
T-
Material skew
Trim removal
Zh -c
Corrugation
OTHER MD TROUGH WRINKLE CAUSES
Misalignment
3-
Zh
~C
D- -C
fcZh
Zh -c
9. Other shear wrinkle causes
Simplex
Concave roller
Bowed spreader roller
D-bar or bent pipe
Duplex
Dual bowed roller
Pos-Z
Expander rollers
Slatted
Banded
Covered
Edge stretchers
Edge pull stretcher rollers
Tenter chains
///. Spreading devices
WEB DEFECTS
TENSION, lb/in.
x- -------- Yield
\
A'
(yc
)CJ
s
/
/
s
/
// /
/"
k/
( 6
Unwinding:
Outside
loosens
ti htens
) z
Unwinding:
Inside
tightens
tl
Winding: inside
loosens
MD
ZD MD
'\f\f\f\f\f\f\.
/ /. Interlayer slippage and the crepe wrinkle
*/
//
'
' /
'
' //
\/s
/^TpX Winding: /
\ Outside
l
B'
/ v.
A"
v.
B"
STRAIN, in./in. or %
Bow method
Tension is not uniform
o
UJ
1. Lay a
long strip
of web
on floor and flatten as best
possible.
Back
Front
Short (tight)
2. Measure bow
(B) & length (L).
Some deckle
positions are
'longer' than
others
-H *k- w
bagginess as:
Bag(%)=I
Back
Front
OO%x4B
2
W/L
Fold method
A"!
3. Calculate
2B->
<H
1. Lay a strip of
web on floor and fold lengthwise
down
middle.
2. Measure bow (B) & length (L).
3. Calculate bagginess as:
Bag(%)=IOO%x4BW/L2
.VJ
-H N-w/2
14. Bagginess measured as camber
diameter of the roller may vary along its face. Then, the highdiameter areas have a faster surface speed than the low-diameter
areas and thus force an in-plane shear stress. While small
diametral variations may be tolerated on some rollers, nipped
rollers are very unforgiving for two reasons. First, the nip pressure
itself is nonuniform. Second, the web cannot slip in a nip to
relieve itself as it could on a wrapped roller.
Several common cases of diagonal wrinkling are shown in
Fig. 9- The corrugation or rope is usually found after surface
winding of a web that has an abrupt caliper variation. Rivers and
lakes are formed when the crowns are not appropriate for a nipped
roller pair (17). Wrinkles can also be generated at nips where the
nip pressure is not uniform on a deformable roll(er) (18). Finally,
any portion of a baggy web that is not sufficiently tightened to
bring it into tension everywhere will likely wrinkle when entering
a nip. This wrinkling happens because the baggy lane gets behind
the rest of the web until it is dragged through in a gulp by shear
stresses.
The partial drive wrinkles form on the boundary of a
driven/braked element that does not span the entire web width.
Material skew occurs when the principal (stiffest) axis of an
anisotropic material is not aligned with the machine direction. The
principal axis of paper from a paper machine and film from a
tenter is oriented straight
VOL79: NO. 10 TAPPI JOURNAL 223
WEB DEFECTS
\
^
AL
D-L
CI*iiAii UA.;.i
~\
Perpendicular
Chalk lines
JL
ti
.Z
MD
Perpendicular
CD
LJ
4. W
i
t
h
s
c
i
s
s
o
The baggy web has two distinct visual differences from the
MD troughs discussed earlier (21). First, the tight and loose bands
are irregularly spaced across the width. Second, the product does
not lie flat and straight. However, it is important to determine if
the web is naturally crooked or is elastically (temporarily) forced
that way through the machine. If the web lies flat on a table but
not through the machine, then the web is not being handled
properly through the machine, perhaps due to causes discussed
earlier. If the web does not lie straight and flat on a table, then you
have a case of residual stresses. A web that does not lie flat on a
table has uneven stresses built into it during manufacturing and, in
some cases, rough handling after manufacturing.
It is helpful to understand what residual stresses are and how
they cause the web to be crooked. Figure 12 shows a stress-strain
curve for a material lying on a table under no external stress. On
this sample are two points labeled A and B. Note how one is
compressive and the other is tensile. Residual stresses indicate
that the web has nonzero stresses inside it, even though no
external stresses are imposed on it.
WEB DEFECTS
KEYWORDS
corrugation, crease recovery, creasing,
design, flattening, rolls, tolerance, web
spreaders, webs, wrinkles.
SUMMARY
LITERATURE CITED
1.
R.,
Tappi
J.
76(6):