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Numerical investigation and optimization of doctor blading in the gravure printing process

Habes, Constantin ; Diehl, Elisabeth ; Sauer, Hans Martin ; Rothmann-Brumm, Pauline ; Ulbrich, Stefan ; Marschall, Holger (2023)
Numerical investigation and optimization of doctor blading in the gravure printing process.
doi: 10.21203/rs.3.rs-3376786/v1
Report, Bibliographie

Abstract

The correct choice of the doctor blade angle is essential in rotogravure printing to achieve efficient removal of excess ink and entrained air for optimal filling of gravure cells. An improper doctor blade angle can lead to the entrapment of air bubbles within or significant underfilling of the engraved cells, which can result in print defects such as voids, streaks, and ink splatter. In this paper, we propose a numerical setup that allows to calculate the optimal doctor blade angle for a given gravure cell shape and ink properties. The doctor blade angle optimization procedure utilizes the Gauss-Newton method while the ink acquisition and doctor blading process is simulated using the Computational Fluid Dynamics (CFD) software OpenFOAM. Moreover, the numerical setup involves a fully automatized geometry generation and meshing procedure which makes the whole setup very flexible and enables its use for further optimization studies.

The findings presented in this paper provide insights into the role of the doctor blade angle in rotogravure printing and show a global trend of smaller angles leading to improved air removal. This result can potentially be exploited to optimize the printing process and reduce print defects.

Item Type: Report
Erschienen: 2023
Creators: Habes, Constantin ; Diehl, Elisabeth ; Sauer, Hans Martin ; Rothmann-Brumm, Pauline ; Ulbrich, Stefan ; Marschall, Holger
Type of entry: Bibliographie
Title: Numerical investigation and optimization of doctor blading in the gravure printing process
Language: English
Date: 2023
Collation: 23 Seiten
DOI: 10.21203/rs.3.rs-3376786/v1
Abstract:

The correct choice of the doctor blade angle is essential in rotogravure printing to achieve efficient removal of excess ink and entrained air for optimal filling of gravure cells. An improper doctor blade angle can lead to the entrapment of air bubbles within or significant underfilling of the engraved cells, which can result in print defects such as voids, streaks, and ink splatter. In this paper, we propose a numerical setup that allows to calculate the optimal doctor blade angle for a given gravure cell shape and ink properties. The doctor blade angle optimization procedure utilizes the Gauss-Newton method while the ink acquisition and doctor blading process is simulated using the Computational Fluid Dynamics (CFD) software OpenFOAM. Moreover, the numerical setup involves a fully automatized geometry generation and meshing procedure which makes the whole setup very flexible and enables its use for further optimization studies.

The findings presented in this paper provide insights into the role of the doctor blade angle in rotogravure printing and show a global trend of smaller angles leading to improved air removal. This result can potentially be exploited to optimize the printing process and reduce print defects.

Uncontrolled Keywords: SFB1194_B07, CFD Simulation, VOF Method, Optimization, Gravure Printing, Forced Wetting, Doctor Blading
Additional Information:

Preprint Article

Divisions: DFG-Collaborative Research Centres (incl. Transregio)
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres > CRC 1194: Interaction between Transport and Wetting Processes
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres > CRC 1194: Interaction between Transport and Wetting Processes > Research Area B: Modeling and Simulation
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres > CRC 1194: Interaction between Transport and Wetting Processes > Research Area B: Modeling and Simulation > B04: Simulation based Optimization and Optimal Design of Experiments for Wetting Phenomena
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres > CRC 1194: Interaction between Transport and Wetting Processes > Research Area C: New and Improved Applications
DFG-Collaborative Research Centres (incl. Transregio) > Collaborative Research Centres > CRC 1194: Interaction between Transport and Wetting Processes > Research Area C: New and Improved Applications > C01: Forced Wetting with Hydrodynamic Assist on Gravure Print Cylinders
Date Deposited: 07 Dec 2023 12:56
Last Modified: 07 Dec 2023 12:56
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