Calendering of metal/polymer composites: An analytical formulation

•We predict the load transferred from polymeric matrices to metallic inclusions.•Our Newtonian and Power Law models show the pressure and stresses profiles.•Parametric analysis on the inclusion stress profiles was performed.•Analytical and experimental pressure profiles were compared.•The Newtonian model has the best correlation with experimental findings.

The process of calendering, or cold rolling, is relevant to geologic processes and industrial applications, ranging from food processing to thin film transistor manufacturing. When dissimilar materials are sandwich stacked and then subjected to extrusion-like deformation between rollers, several factors influence the outcome of the product composite. In this work, Newtonian and Power Law models are developed to predict the pressure and stresses experienced by the materials during calendering. Experiments with polymer/metal sandwiched layers inform the parameters used in the models and allow for validation. A parametric analysis is conducted to further explore the influence of material and processing parameters. The pressure profiles predicted by the models are compared to experimental results of the pressure sensor data and the parameters leading to inclusion fracture in the six composite material combinations explored. The Newtonian model is found to have the best correlation with experimental findings.