Simultaneous high- and low-angle particle impact during wear of metering blades used in paper coating

Coating blades are used in the paper industry to meter off the excess coating applied to the paper. They are essential in attaining high-quality coating films with minimum operating cost. During the coating process, the blades are worn down at the tip and are replaced when the coating quality degrades. The objectives of this study are to predict the wear rate of the blades and examine the hypothesis that the blades wear into a quasi-steady-state wear profile, despite both low- and high-angle particle impact. Experimental data and results from finite element simulations are presented for a series of blade materials and suspensions. The approach taken differs considerably from earlier studies, in that it treats blade wear as erosion from the action of the impacting slurry particles rather than abrasion, thus explaining the enhanced wear around the heel. The current approach relies on computer experiments to solve the equations for the liquid flow field, the individual particle motion, the substrate deformation and the eroded volume of the blade, rather than employing empirical relations between wear rates and average fluid velocity. The shear thinning behavior of the coating suspension was properly taken into account. To validate the calculations, blade samples from both a pilot and an off-machine coater were collected at a variety of time intervals. The blade samples aided not only in the establishment of the wear rates and the identification of the wear patterns, but also in the confirmation of the steady-state wear hypothesis that is correctly predicted by the simulations.