Trough Analysis of Polymer Film Transport Using Finite Element Method and Experimental Evaluation Using Image Analysis

In roll-to-roll production systems, wavy defects known as troughs may occur during conveying. Finite element method (FEM) simulations have been employed to predict the occurrence of such troughs, but few studies have compared results from FEM analysis with actual conveying conditions. In this study, image analysis of troughs by stereo digital image correlation (DIC) was carried out under the same conditions to assess the behavior of polymer film during conveying by FEM simulation and to validate the simulation. Three patterns of film thicknesses of 6, 12 and 25 μm were used in the experiments, and similarly only the thickness condition was changed in the FEM analysis. Comparison results showed that the trends of trough changes when the DIC and FEM conditions were changed were consistent. Therefore, the validity of the prediction of trough occurrence by FEM analysis was confirmed.