An advanced model for the numerical analysis of the radial stress in center-wound rolls

• We develop a novel radial stress model that considers gravity and bending stiffness.
• Estimation accuracy of the developed model is verified experimentally.
• Effects of gravity and elastic modulus of wound roll on radial stress are analyzed.
• Developed model can be used for estimating radial stress from winding conditions.
• Simulation gives insights on radial stress behavior based on winding conditions.

In the case of roll-to-roll systems, winding is an important process and determines the quality of the final products. During the winding process, the winding tension determines the distribution of stress in the radial direction, i.e., the radial stress in the wound rolls. In order to optimize the winding tension, it is essential to have a model that can estimate the radial stress caused by the tension. However, to the best of our knowledge, no radial stress model that considers the effects of gravitation and the bending stress in the wound roll has yet been reported. In this study, we developed an advanced radial stress model that considers the effects of both these parameters on the radial stress. The accuracy of the developed model was verified experimentally for wound rolls of various materials. Finally, the effects of gravitation, the bending stress, and the winding tension on the radial stress were analyzed using the model. The model was found to be useful for analyzing the tension induced during the winding of several materials. Furthermore, the results of the performed analysis provided insights regarding how the radial stress is affected by the characteristics of the material being wound and the winding tension.