Three-dimensional flow simulation of a film-casting process

Three-dimensional now simulation of a film-casting process was performed using a finite element method assuming an isothermal and steady Newtonian now. The simulation was carried out under industrial operation conditions. The neck-in and the edge bead phenomena could be simulated. The effects of draw ratio, air gap length, and die width on these phenomena are discussed. The neck-in and the edge bead phenomena were affected by the draw ratio and air gap length and not by the die width. The neck-in value, which was defined as the difference between the die width and film width at the chill roll. Increased with the draw ratio and air gap length.