Effect of inertia and gravity on the draw resonance in high-speed film casting of Newtonian fluids

The interplay between inertia and gravity is examined for Newtonian film casting in this study. Both linear and nonlinear stability analyses are carried out. Linear stability analysis indicates that while both inertia and gravity enhance the stability in film casting, inertia plays a more dominant role regarding the critical draw ratio. In contrast, the disturbance frequency is more sensitive to the effect of gravity. The nonlinear results show that at the critical draw ratio, the system oscillates harmonically, indicating the onset of a Hopf bifurcation. For a draw ratio above criticality, finite-amplitude disturbances are amplified, and sustained oscillation is achieved. It is found that the growth rate increases with draw ratio, but decreases with inertia and gravity, which suggests that initial transients tend to take longer to die out for a fluid with inertia and gravity. Transient post-critical calculations show that the nonlinearity can be effectively halted by inertia and gravity. The oscillation frequency (film-thickness amplitude) decreases (increases) with draw ratio. However, the film oscillates more frequently but less fiercely with stronger inertia and gravity effects. The rupture of the film is also examined, and is found to be delayed by inertia and gravity. Interestingly, although the oscillation amplitude is found to be weakest at the chill roll, it is at this location that the film tends to rupture first.