Document Name: 0101R273

Section: TAPPI PRESS

Title: The Mechanics of Web Handling

BOOK
The Mechanics of Web Handling
By David R. Roisum

1998. 222 pages, soft cover

Item Number: 0101R273
ISBN:089852346X

The Mechanics of Web Handling is the third book in Dave Roisum's trilogy. The
Mechanics of Winding and The Mechanics of Rollers are also available from TAPPI
PRESS.

This unique book covers many aspects of web handling for manufacturing, converting, and
printing. The book is applicable to any web including paper, film, foil, nonwovens, and
textiles. The Mechanics of Web Handling is designed for product, process, and
maintenance engineers responsible for web machinery. Through this valuable text, readers
will better understand how to design and operate machinery to avoid wrinkles, web breaks,
registration, guiding, and other types of costly web problems.

Fourteen chapters cover the following topics:

l Introduction to Web Handling

l Material Mechanics
l Dimension Control
l Tension and Tension Control
l Downweb Tension Variations
l Crossweb Tension Variations
l Temporal Tension Variations
l Guiding
l Nips
l Slitting
l Spreading
l Winding
l Wrinkling
l Web Breaks

TABLE OF CONTENTS
1 Introduction to Web Handling 8 Bibliography

1 What is a web? 2 Material Mechanics

2 Web Materials and Industries
3 Web Converting 9 Material Matters
4 Web Handling 10 Tensile Test
5 Web Mechanics 11 Stress-Strain Curve
6 Web Handling Opportunities 12 Brittle and Ductile Materials
7 Other Web Handling Resources 13 Poisson's Ratio

Page 1 of 8
 The Mechanics of Web Handling
Table of Contents
14 Hygro-Thernal Expansion 75 Tension Variations Across Web Length
15 Anisotropy 77 In-plane Misalignment and Bending
16 Hooke's Law 78 In-plane Example Problem
17 Creep and Stress Relaxation 79 High In-plane Misalignments
18 Hysteresis, Memory and Set 80 Out-of-plane Twisting
19 Static Coefficient of Friction 81 Diagonal Shear Wrinkles
20 Friction Complications 82 Manual Alignment Checks
21 Test Frequency 83 Roller Diametral Variations
22 Units 85 Partial Drive
23 Bibliography 85 Path Length Variations
86 Baggy Webs
3 Dimensional Control 89 Bibliography

25 Product Geometry 7 Temporal Tension Variations

26 Basis Weight
27 Caliper 91 Time Varying Tension
28 Length 92 Drive Sensor Resolution
29 Width 94 Drive Actuator Resolution
30 Bulk ad Density 94 Steady State vs. Transient Response
31 Roll Bulk 95 Speed Changes
31 Roll Stresses and Bulk Loss 95 Speed Reference
32 Roll Firmness 96 Multiple Drive Sections
33 Roll Bulk and Firmness 97 Web Time Constants and Transport
34 Roll Weight 97 Drive Time Constants
35 Registration 98 Selected Bibliography
38 Wound Roll Width Variations
39 Wound Roll Offsets 8 Guiding
40 Telescoping and Dishing
41 Length and Speed Measurement 99 Guiding Introduction
42 Incremental Encoder Applications 100 Camber
43 Resolving Length Differences 101 Acceleration Offset
44 Measuring Waste and Efficiency 102 Passive Guides
47 Bibliography 103 Unwind Guide
103 Rewind Guide
4 Tension and Tension Control 104 Steering Guide
106 Displacement Guide
49 Why Web Tension is Important 107 Oscillation
50 Choosing a Process Tension 108 Bibliography
51 Tension Exceptions
52 How Close Must Tension Be Held 9 Nips
53 Load Cell Tension
54 Load Cell Sizing Example 109 Nipped Rollers for Web Transport
55 Other Load Cell Considerations 110 Nipped Rollers for Web Processing
56 Dancer Controlled Tension 111 Hertzian Contact
57 Dancer Design 112 Determining Peak ZD Nip Stress
58 Dancer Dynamics 113 A Rubber Covered Roller Model
59 Draw Control 114 Complex Nip Models
60 Tension Variations in a Draw Zone 115 Interior Contact Stresses
61 Catenary (Loop) Control 116 Nip Loading Mechanisms
62 Tension from Motor Readings 117 Nip Load System Friction
63 Curent Control 118 Load Versus Gap Control
64 Bibliography 119 Roller Deflection in a Nip
120 Crowning
121 Load Crown Match
5 Downweb Tension Variations 122 Deflection Compensating Techniques
123 Roller Geometrical Errors
65 Tension Down Through a Machine 124 Nip Impressions
66 Roller Drag 125 Static Nip Impressions
68 Inertial Tension 126 Dynamic Nip Impressions
70 Band Brake and Tension Difference 127 Bibliography
71 Load Cell or Dancer Sections
72 Draw or Speed Controlled Sections 10 Slitting
73 Downweb Tension Summary
74 Bibliography 129 Slitting Issues
130 Slitting System Options
6 Crossweb Tension Variations 131 Laser Slitting

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 The Mechanics of Web Handling
Table of Contents
131 Razor Slitting 190 Bibliography
132 Score Slitting
133 Shear Slitting Appendices
136 Waterjet Slitting
137 Trim Removal 191 A Units and Conversions
138 Other Cutting Methods 192 B1 Selected Bibliography
139 Bibliography 198 B2 Some Web Handling Resources
199 C Calculations and Formulae
11 Spreading
205 Glossary
141 Introduction
142 Spreading Principles 217 Index
143 Concave Spreader Roller
144 Bowed Spreader Roller
147 Bent Pipe and D-Bar Spreaders
148 Dual Bowed Roller Spreader
149 Pos-Z™ Spreader
150 Edge Pull Web Stretchers
151 Compliant Cover Rollers
152 Grooving
153 Spreading Is Temporary
154 Flattening
155 Is My Spreader Working?
156 Bibliography

12 Winding

157 Why Wind?

158 Winder Classes and Arrangements
159 The TNT of Winding
160 Roll Structuring
161 Roll Structure Measurement
162 Wound Roll Stresses
163 Interlayer Slippage
164 Roll Edge Quality
165 Roll Quality
166 Bibliography

13 Wrinkling

167 Wrinkling Introduction

168 Compressive Buckling of Webs
169 Constrained Expansion
171 Other MD Trough Wrinkling Causes
172 Diagonal Shear Wrinkles
172 Roller Misalignment
173 Shear Wrinkling Regimes
174 Other Diagonal Wrinkling
175 CD Wrinkles and Winding
176 The Baggy Web
178 Baggy Web Troubleshooting
179 Bibliography
180 Bibliography - Selected Tension Measure

14 Web Breaks

181 Importance of Runnability

182 Defining Runnability
182 Environmental Considerations
183 Load-Strength Distributions
184 Can Lab Tests Predict Runnability?
185 Pilot Machine Testing of Runnability
186 Flaws and Fracture
187 Runnability Troubleshooting
188 Break Phone Processes
189 Web Break Troubleshooting Checklist

Page 3 of 8
 Subject Index
Abrasives - 130 Compressibility - 33
Absorbency - 30 Concave Roller - see Spreading
Acceleration Offset - see Speed, Accel Offset Coning - see Wound Roll Telescope
Acceleration Rate - see Speed, Changes Control - see Dancer, Nip, Tension etc
Adhesve - 40, 130, 131, 132 Converting
Aging - 17 Definition - 3
Air Entrainment Industry - 2,3
Nipped Rolls - 109 Covers - see Roller Covers
Rollers - 49 Creep - 17
Winding - 4, 175 Crown - see Roller, Diameter Variation
Air pressure - see Pneumatics Current Control - 63
Air Resistance - 66 Customer - see also Product Spec - 46, 167
Alignment - see Misalignment Dbar - see Spreading
Anelastic Effects - 17 Dancer - see also Tension, Load Cell
Angel Hair - see slitting Calibration - 55
Anisotropy - 15 Design -56-58
Axes - 1 Friction - 93
Baggy Web Response - 97
and Bowed Roller - 146 Databases - 7
and Guiding - 100 Density
Definition - 176 and Bulk - 30
Measurement - 88, 176, 177 Caliper Affects - 26
Slack Edge - 75, 76, 86, 87 General - 22
and Spreading - 141 and Roll Weight - 34
Stress Distribution - 176 Diameter Variations - see Roller, Diameter
Tension Variations - 75, 76, 86, 87 Die cut - 138, 110
Troubleshooting - 176 Documentation - 187
Web Breaks - 187 Darg - 65-67, 91
Wrinkling - 86, 174 Draw Control - see Speed Control
Bar - see also Spreading, Dbar - 85, 102 Drawing (Process) - 51, 93
Basis Weight - 22 Drive - see also Response and Speed and Tension
Defining - 26 Bowed Roller - 144
Measurement - 26 Feedforward - 96
and Roll Weight - 28, 34 Helper - 73
Bearing Mechanical Losses - 66
Bowed Roller - 144 Resolution - 94
Drag - see Drag Sections - 96
Belt - 84, 94, 102, 107 Ductile - 12, 51, 186
Bent Pipe - see Spreader, Bent Pipe Dust - see Slitting
Blocking - see Wound Roll Economics - see also Waste - 157
Books - 7 Efficiency - see Waste
Bowed Roller - see Spreading, Bowed Roller Electronics - 55
Breaks - see Runnability Embossing - 110
Brittle - 12, 61, 181, 186 Encoder - see Speed Measurement
Buckles - 9 Film - 9, 15, 131
Buckling - 168, 169 Flutter - 49
Bulk Folding - 142
Definition -30 Footage Counter - see Length
Measurement - 30 Foundations - 17
Roll - 31 Flattening - 151, 153
and Slitting - 130 Flatness - 12
Calender Fracture Mechanics - 186
Nips - 110 Friction
Web Breaks - 181 Affects - 19
Caliper - see also Basis Weight and Density Dancer - 56
and Bulk - 30 Kinetic - 19
General - 22, 26 Measurement - 19-20
Measurement - 27 Roller-to-Web - 70
and Roll Weight - 28 Static - 19
and Tension Settings - 50 Gauge - 22
and Wrinkling of - 86, 167, 168, 173 Geometrical Control - 17, 49
Camber - see Baggy Web Grooving - see Roller, Grooving
Cantilevered - 76 Guiding
Catenary (Tension) Control - 61 Displacement - 106
Coating - see Wrinkling, Expansive General - 99
Chemistry - 9 Edge Pull - 150
Compensator - 35 Oscillation - 103

Page 4 of 8
 Subject Index
Passive - 102 and Baggy Webs - 86
and Registration - 36, 99 Crowning - 120
Response - 104-106 Footprint - 111
Spans - 104-106 Impressions - 124-126
Steering - 104 Load Control - 116-118
Unwind - 103 Rolling Resistance - 66
Winder - 103 and Spreaders - 153, 155
Hooke's Law - 16 Stresses - 111-115
Humidity - see Moisture Uniformity - 119-125, 123
Hygroscope - see Moisture Units - 22
Hysteresis - 18 and Web Breaks - 181, 188
Inertia Winding - 159, 160, 163, 109
Compensation - 68 Winding Defects - see Wound Roll
Dancer - 58 and Wrinkling - 174
Tension Effects - 68, 69 Nip Induced Defects - 19
Isotropy - 15 Nonwovens - 9, 13, 30, 136
Laminating - 51, 96, 99, 110 Normal Entry Law - 101, 142, 145
Layflat - see Flatness Offsets - see Wound Roll Offsets
Length - see also Speed Operators - 72
General - 25 Organizations - 7
Measurement - 28, 41-43 Orthotropy - 15
and Registration - 36 Oscillation - 103, 107
and Waste - 48 Oven - 101, 104, 170
Level - see Misalignment Packaging - 30, 33, 157
Lineshaft - 35 Paper
Load Cell - see Tension, Load Cell Friction - 19
Loop - see Tension, Catenary Industry - 1
Machine Builders Moisture - 14
Expertise - 7 Skew - 15
Magazines - 7 Path of Web - see also Guides and Spreaders - 49,
Maintenance 83, 99, 101, 106, 142, 145, 147, 153
Roller - 66, 82-84, 101 Pipe - see Bar
Tension Control - 55, 56, 94-95, 101 Plates - 5
Slitting - 129, 132, 135 Pneumatics - 63, 94
Material Poisson Radio - see also Width - 29, 169
Properties - 5, 9-22, 184 Principle Axes - 15
Membrane - 5 Printing
Memory - 18 Dust - 129
Misalignment Industry - 2
Alignment Methods - 172 Nips - 110
Foundation Creep - 17 Registration - 35
Inplane - 77-79 Web Breaks - 181, 188
Measurement - 82 Wrinkling - 170
Parallel - 82 Process
and Path - 101, 147 Design - 3
Square - 82 Product
and Tension Variations - 76-82, 173 Design - 3, 6
and Web Breaks - see Runnability Examples - 2
and Wrinkling - 169, 172, 173 Specifications - 25, 33, 43, 45
Modulus Productivity - see also Speed - 158, 181
and Caliper - 27 Pull Roller - see Roller
and Draw Control - 59, 60 Quality Control - 10, 21
of Elasticity - 9, 11 Razor Slitting - see Slitting
of Rupture - 11 Registration - 35, 51, 60, 86, 91, 99
and Tension Set - 51 Repeat - 35
of Toughness - 11 Resonance - 58, 97
Units - 22 Response - 91, 95
Mohr's Circle - 168 Ridges - 9
Moisture - see also Temperature Roll - see Wound Roll
and Basis Weight - 26 Roller
and Length - 28 Bearing Drag - see Drag
and Tension - 60, 72 Counts - 6, 67, 69, 71
and Web Breaks - 12, 181, 182 Covers - 18, 110, 113, 115
and Width - 29 Crowning - 120, 121
and Wrinkling - 169 Deflection - 76, 119-122, 169, 171
Narrow Web - 82 Design - 6
Nip Diameter Variations - 83, 102, 171, 174

Page 5 of 8
 Subject Index
Grooving - 152, 171 Guides - 104-106
Inertia - see Inertia Length - 77
Importance - 5 and Wrinkling - 173
Misalignment - see Misalignment Specifications - see Product Specifications
Pull - 109 Speed - see also Length
Sizing - 4, 49 Acceleration Offset - 101
Slippage - 40, 70 Changes - 65, 68, 94, 95
Tolerances - 6, 71, 123 Control - 9, 59, 60, 72, 159
Tractions - 20, 49, 60, 70, 95, 142, 109 Encoder - 8, 41, 42
Wrap Angle - 70, 142, 154 Limits - 4
Rolling - 110 Measurement - 41, 93
Roughness - 27 Reference - 95, 96
Definition - 182 Slitting - 130, 132, 133, 134
Flaws - 186 Spreading
Fracture Mechanics - 186 and Baggy Webs - 178
General - 9, 12, 49 Bent Pipe - 85
Proof Testing - 189 Bowed Roller - 85, 144-146, 173
and Roller Alignment - 79, 172, 173, 187 Compliant Cover - 151
and Strength - 183 Concave Roller - 84, 143
and Tension - 183-185 Dbar - 141
Testing - 185 Definition - 141, 142, 155
Troubleshooting - 187-189 Dual - 148-149
Web Break Detectors - 187 Duration - 141, 153
Safety - 129 Edge Pull - 150
Sag - see Tension, Catenary Evaluation - 155
Set - 18 Expander - 150
Score Slitting - see Slitting Flattening - 151, 154
Shear - 16 Forces - 142
Shear Slitting - see Slitting Locations - 153, 155
Sheeting - 138 Measurement - 151, 155
Shipping - 30-31 and Misalignment - 80
Slippage - see Length Measurement Pos-Z - 149
Skew Sizing - 144, 145
Material - 15 and Span Length - 85
Roller - 85 Tenter - 150
Slack Edge - see Baggy Web and Traction - 141, 142, 145, 150
Slitter Rewinder - see Winding Width Change - 16
Slitting Wrap Angle - 142, 146, 148
Angel Hair - 129 Square - see Misalignment
Cant Angle - 135 Stability - 91
Difficulties - 129, 130 Standards - see Testing
Dust - 129 Static Electricity - 20
General - 13 Statistics - 182, 183, 187
Grinding - 132, 134 Steering - see Guide or Path
Handling - 134 Storage - 17
Laser - 131 Strength
Life 129, 131, 132 and Tension Setpoint - 10, 50, 51
Metallurgy - 134 Tensile - 10, 22
Options - 130, 138 Ultimate - 11
Overlap - 135 Units - 22
Quality of Cut - 129 Yield - 11
Rake Angle - 135 Stress Relaxation - 17
Razor - 131 Stretch - 10
Rings String - 5
Safety - 129 Tachometer - see Speed, Measurement
Score - 132 Tape - 143
Sharpness - 129, 131, 132 TAPPI - ii, 27
Shear - 133-135 TEA - 11
Sideload - 134 Telescoping - see Wound Roll Telescope
Waterjet - 136 Temperature - see also Moisture
Web Breaks - 181, 188 General - 12, 14
Width Setup - 25 and Length - 28
Wrinkling - see Wrinkling, Expansive and Tension - 72
Smoothness - 27 and Web Breaks - 181
Solvents - 14, 170 and Width - 29
Span and Wrinkling - 169, 170
Geometries - 5 Tension and Tension Control

Page 6 of 8
 Subject Index
General - 6 Goals - 4
Catenary - 61 History - 4
Draw - see Speed, Control Laws - 5
Drive - 65 Wheels - 85, 174
Importance of - 49 Width
Isolation - 60 General - 25
Load Cell - 53-55, 71, 75, 76, 92, 97 and Registration - 36
Low Tension - 61 Roll - 29, 38 40
Motor Amps - 62 Slitter Setup - 25
and Registration - 35 and Spreading - 141
Response - see Response and Tension Control - 76
Setpoint - 9, 50 Tension Effects - 13
and Slitting - 131 Width Tolerances
Speed - see Speed, Control Poisson Radio - 9, 13
Tolerances - 52, 57, 92, 93 Winder - see Winding and Wound Roll
Units - 22 Winding - see also Wound Roll
and Web Breaks - 183 Centerwind - 158
Winding - 159 CenterSurface Wind - 158
Tension Variations Interlayer Slippage - 115, 163, 164, 175
Across Width - 75-89, 100, 176 Nip - 159, 160, 163
Baggy Web - see Baggy Web Purpose - 157
Drive - see Tension Control Roll Structure - 160
and Guides - 102, 104-106 Roll Structure Measurement - 161
Measurement Across Width - 75 Speed Difference - 159
and Path - 101 Surface Wind - 158
and Time - 91-97 Tension - 159
and Web Breaks - 183, 187 TNT's - 159
and Wrinkling - 169 Torque - 159
Tenter - 150 Turnup - 188
Testing Web Breaks - 188
Economics - 21 Wound Roll
Frequency - 21, 184 Blocking - 162, 175
Standards - 10, 26, 27 Bulk - 31-33
Tensile - 10, 184 Compressibility - 33
and Web Breaks - 184 Coning - see Wound Roll Telescope
Textiles - 136 Corrugations - 174
Time - 35 Defects - see Wound Roll, Quality
Time Constant - 60 Diameter - 28, 31, 33, 34
Tissue - 30-33 Dishing - 40
Tolerances - 52-54 Edge Quality - 39, 40, 103, 164
Torque (Drive) - 22, 63, 159 Firmness - 32, 33
Tracking - see Path of a Web Flat Spot from Storage - 17
Traction - see Roller Traction Length - see Length
Tram - see Misalignment Measurements - 32, 161
Trim - 44, 85, 137, 174 Nip Induced Defects - 163, 175
Troubleshooting - ii, 175, 178 Offsets - 39
Twisting - 80, 104-106, 142, 148 Quality - 161, 164, 165, 175
Ultimate Strain - see Stretch Ridges - 84
Uniformity - 51 Specifications - see Wound Roll Quality
Unwind Stresses - 29, 31-33, 38, 162
Web Breaks - 187 Telescope - 19, 40, 163, 175
Yield - see Strength, Yield Tensioning - 159
Vibration - 19, 55 Weight - 28, 34
Waste - 43-46, 157, 181 Width - see Width
Waterjet - see Slitting Wound-in-Tension - 159
Weave - see Path of Web Wrap Angle - see Roller, Wrap Angle
Web Wrinkling
Breaks - see Runnability Buckling - 168, 172
Heavy - 51 Bowed Roller - 144, 145
Lightweight - 51 Definition - 167
Materials - 1 Expansive - 14, 153, 169
Modulus - see Modulus General - 6
Products - 2 Grooving on Rollers - 152
Properties - 1 Material Skew - 15
Web Handling Nip - 109
Areas of Study - 4 Roller Deflection - 76
Definition - 1, 4 Shear - 81

Page 7 of 8
 Subject Index
and Spreaders - 141-155
Slitting - 133
Tension Effects - 49, 81
Web Breaks - 188

Page 8 of 8