Winding Machines, Mechanics and Measurements

This new book, by two of the world's foremost experts, is the definitive guide to how winding machines work and how wound rolls are formed. It covers a wide array of machines in use across all web industries, including paper, film, foil, nonwovens, textiles, and more. It sets the standard for understanding and applying quality control in the field. Using hundreds of proven calculations, the book enables readers to understand and make the adjustments necessary to prevent roll defects and improve product quality. Dozens of examples and hands-on applications illustrate key techniques. Most of the book, especially the last section on measurement, is written in everyday language accessible to all responsible for machine operation and roll quality—from engineers to shop floor managers.-------------------------------------------------------------------------------- TABLE OF CONTENTS Preface About This Book and CD-ROM Section I—MACHINES 1. Zen and the Art of Winding · The TNT's of Winding · Winder Classes · Limits on Tension, Nip and Torque Differential · The Effect of Class on Range of Wound Roll Tightness · What is Tightness? · How Does Winding Being a One-Knob Process Affect Winding Strategy? · What Class is Best and How Many Knobs Do I Need? · What About Taper or Roll Structure? · How Do You Set Taper? · A Few Words About Optimization—What is the Best Tension? · Bibliography 2. Some Winding Defects · DFM Applied to Winding · Getting Started · What is a Defect? · Blocking · Core—Crushed · Core—Loose · Corrugations or Ropes · Curl · Gauge Bands or Ridges · Hardness Variations Across a Roll · Nip Induced Defects · Offsets and Rough Roll Edges · Out-of-Round Roll · Starring and Related Defects · Telescoping · A Note on Oscillation · Summary · Bibliography 3. Winder Arrangements · Selecting a Winder · Salvage Winders · Turret Winders · Reels · Duplex Winders · Two Drum Winders · Grooving, Traction Coated and Rubber Covered Drums · Gap Winders · Bigger is Better for Drums, Spools, Cores and Rollers · Supporting Large Rolls on Drums · Summary · Bibliography 4. Roll Geometry and Properties · Roll Diameter · Roll Length · Resolving Roll Length Discrepancies · Roll Width · Wound Roll Offsets and Rough Edges · Telescoping and Dishing · Roll Weight and Density · Some Useful Roll Conversion Formulas · Bibliography Section II—MECHANICS 5. Simple Material Properties · Basis Weight · Caliper · Caliper Profile—A Very Important Note · Density or Bulk · Other Web Material Properties of Winding Interest · Other Roll Properties of Winding Interest · The Fiber Core—The Foundation of Most Wound Rolls · Bibliography 6. Introduction to Wound Roll Modeling · Stresses in a Wound Roll · Anisotropy and Principal Axes · MD or Tangential Modulus · ZD or Radial Modulus · In-Plane Poisson Ratio · Poisson Ratios for Winding Models · Basic Equations of Winding Models · Winding Equation · Core Modulus Ec—The Inner Boundary Condition · Winding Tightness—The Outer Boundary Condition · Bibliography 7. Simple 1-D Models · Early Models 1950-1985 · Hakiel's Models—1986 · Early Complex Models · Early Experimental Verification · The Hakiel Formulation · Spongy and Fully Compressed Behavior · Constant Tension versus Constant Torque · Large Deformations · Plane Strain versus Plane Stress Winding Models · Bibliography 8. 2-D Models and Gauge Variation · Measuring Gauge Profile · Early Models of the Effects of Gauge Variation · True 2-D Models of the Effects of Gauge Variation · Summary of the Effects of Gauge Variation · Bibliography 9. The Effect of Nip on Wound Roll Stresses · Classes of Winders · What is WOT? · Early Experimental Evidence of WOT · Early Models for WOT · Comparative Study of Different Models for WOT · WOT on Two Drum Winders · Summary of Findings · Bibliography 10. The Effects of Air Entrainment · Air Entrainment Between Webs and Rollers · When Is Air Important Between Permeable Webs and Rollers/Wound Rolls? · Some Practical Observations on Entrained Air · A