Simulation of non-Newtonian ink transfer between two separating plates for gravure-offset printing

The inks used in gravure-offset printing are non-Newtonian fluids with higher viscosities and lower surface tensions compared to Newtonian fluids. This paper examines the transfer of a non-Newtonian ink between two parallel plates when the top plate is moved upward with a constant velocity while the bottom plate is held fixed. Numerical simulations were carried out using the Carreau model to explore the behavior of a non-Newtonian ink in gravure-offset printing. The volume of fluid (VOF) model was adopted to demonstrate the stretching and break-up behaviors of the ink. The results indicate that the ink transfer ratio is greatly influenced by the contact angle, especially the contact angle at the upper plate (α). For lower values of α, oscillatory or unstable behavior of the position of minimum thickness of the ink between the two parallel plates during the stretching period is observed. This oscillation gradually diminishes as the contact angle at the upper plate is increased. Moreover, the number of satellite droplets increases as the velocity of the upper plate is increased. The surface tension of the conductive ink shows a positive impact on the ink transfer ratio to the upper plate. Indeed, the velocity of the upper plate has a significant influence on the ink transfer in gravure-offset printing when the Capillary number (Ca) is greater than 1 and the surface tension dominates over the ink transfer process when Ca is less than 1.