18.2.2. Flow Equations

The film is assumed to be geometrically described in the - plane. Let stand for the Cauchy stress tensor, and for the velocity vector. On the upper and lower free sides of the film, zero traction conditions apply. In view of the small film thickness, it is assumed that this is true across the film thickness. From the vertical momentum equation, the pressure, , can be found:

(18–1)

That is,

(18–2)

where is the extra-stress component that obeys the fluid constitutive equation. Because the divergence of the velocity is equal to zero, the following equation holds:

(18–3)

where is the coordinate in the film-thickness direction.

Let be the thickness of the film, equal to the value of at the upper side of the film. Mass conservation on a film element of thickness yields

(18–4)

where the term involving the partial derivative of the thickness with respect to time is omitted in steady or evolution calculations. This partial differential equation (Equation 18–4) is of the hyperbolic type. From a mathematical viewpoint, a boundary condition for the thickness must be specified along a line crossing all flow trajectories at their entrance into the computational domain. In the geometric model, this line corresponds to the die exit, and hence to the film entrance. Note that the thickness must be specified only along this line.

18.2.2.1. Boundary Conditions

When solving a film problem, the thickness-averaged velocity field, which is a function of and , will be calculated. As in any flow problem, flow boundary conditions must be specified. General information on boundary conditions can be found in Boundary Conditions. When a nonisothermal film flow is solved, an average temperature equation will be calculated as well. This field obeys the energy equation. Boundary conditions must therefore be specified for the temperature field.

18.2.2.2. Stress Boundary Conditions for the DCPP Model in Film Casting

For the particular case of the DCPP model used within a film casting flow simulation, care may be required when imposing the boundary conditions for the viscoelastic variables at the inlet of the calculation domain. The inlet is identified as the border where the thickness condition is imposed. Here, instead of imposing values for all components of the orientation tensor, you will be asked about anisotropy described in terms of orientation and factor, as well as stretching amplitude. Imposing boundary conditions for the viscoelastic unknowns (orientation and stretching) is optional. If conditions are imposed, you will need to provide the following information:

  • the direction of anisotropy of the orientation tensor ( or )

  • the anisotropy factor ranging between 0 (isotropic) and 1 (anisotropic)

  • the inlet stretching