Finite element analysis of calendering

Abstract The general equations describing the flow of Newtonian and non‐Newtonian fluids in the gap of two calender rolls were simplified by making use of the lubrication approximation. The resulting equations were solved by the finite element method. The results are in excellent agreement with existing analytical solutions for Newtonian fluids. New results were obtained for pressure, velocity profiles and sheet thickness of non‐Newtonian fluids for symmetric and asymmetric calendering (different roll diameters, different roll speeds). The solution of this problem demonstrated the great possibilities offered by the finite element method in solving Theological problems of practical significance, particularly whenever complicated wall boundaries or free surfaces are involved.