Numerical Modeling of the Side Flow in Tape Casting of a Non-Newtonian Fluid

One of the most common ways used to produce multilayer ceramics (MLC) is tape casting. In this process, the dried tape thickness is of great interest to control the desired products and applications. One of the parameters that influences the final tape thickness is the side flow factor (a) which is mostly measured at the end of the process by a volumetric comparison of the tape which flowed outside the casting width to the tape within the casting width. This phenomenon has not been predicted theoretically yet in the literature. In this study, the flow of (La0.85Sr0.15)0.9MnO3 (LSM) slurry in the tape casting process is modeled numerically with ANSYS FLUENT in combination with an Ostwald-de Waele power law constitutive equation. Based on rheometer experiments, the constants in the Ostwald-de Waele power law are identified for the considered LSM material and applied in the numerical modeling. This model is then used for different values of substrate velocity, initial doctor blade height and material load in the reservoir, to investigate their effect on a. It is found that this factor mostly ranges between 0.8 and 0.9. Results of the modeling are compared with experimental findings and good agreement is found.