Winding

List of Figures
List of Tables
Foreword by James N. Dobbs, 3M Company
Preface
Introduction
Acknowledgements

Section I—MACHINES

1. Zen and the Art of Winding

• The TNT’s of Winding
• Winder Classes
• Limits on Tension, Nip and Torque Differential
• The Effect of Class on Range of Wound Roll Tightness
• What is Tightness?
• How Does Winding Being a One-Knob Process Affect Winding Strategy?
• What Class is Best and How Many Knobs Do I Need?
• What About Taper or Roll Structure?
• How Do You Set Taper?
• A Few Words About Optimization—What is the Best Tension?
• References

2. Some Winding Defects

• DFM Applied to Winding
• Getting Started
• What is a Defect?
• Blocking
• Core—Crushed
• Core—Loose
• Corrugations or Ropes
• Curl
• Gauge Bands or Ridges
• Hardness Variations Across a Roll
• Nip Induced Defects
• Offsets and Rough Roll Edges
• Out-of-Round Roll
• Starring and Related Defects
• Telescoping
• A Note on Oscillation
• Summary
• References

3. Winder Arrangements

• Selecting a Winder
• Salvage Winders
• Turret Winders
• Reels
• Duplex Winders
• Two Drum Winders
• Grooving, Traction Coated and Rubber Covered Drums
• Gap Winders
• Bigger is Better for Drums, Spools, Cores and Rollers
• Supporting Large Rolls on Drums
• Summary
• References

4. Roll Geometry and Properties

• Roll Diameter
• Roll Length
• Resolving Roll Length Discrepancies
• Roll Width
• Wound Roll Offsets and Rough Edges
• Telescoping and Dishing
• Roll Weight and Density
• Some Useful Roll Conversion Formulas
• References

Section II—MECHANICS

5. Simple Material Properties

• Basis Weight
• Caliper
• Caliper Profile—A Very Important Note
• Density or Bulk
• Other Web Material Properties of Winding Interest
• Other Roll Properties of Winding Interest
• The Fiber Core—The Foundation of Most Wound Rolls
• References

6. Introduction to Wound Roll Modeling

• Stresses in a Wound Roll
• Anisotropy and Principal Axes
• MD or Tangential Modulus
• ZD or Radial Modulus
• In-Plane Poisson Ratio
• Poisson Ratios for Winding Models
• Basic Equations of Winding Models
• Winding Equation
• Core Modulus Ec—The Inner Boundary Condition
• Winding Tightness—The Outer Boundary Condition
• References

7. Simple 1-D Models

• Early Models 1950-1985
• Hakiel’s Models—1986
• Early Complex Models
• Early Experimental Verification
• The Hakiel Formulation
• Spongy and Fully Compressed Behavior
• Constant Tension versus Constant Torque
• Large Deformations
• Plane Strain versus Plane Stress Winding Models
• References

8. 2-D Models and Gauge Variation

• Measuring Gauge Profile
• Early Models of the Effects of Gauge Variation
• True 2-D Models of the Effects of Gauge Variation
• Summary of the Effects of Gauge Variation
• References

9. The Effect of Nip on Wound Roll Stresses

• Classes of Winders
• What is WOT?
• Early Experimental Evidence of WOT
• Early Models for WOT
• Comparative Study of Different Models for WOT
• WOT on Two Drum Winders
• Summary of Findings
• References

10. The Effects of Air Entrainment

• Air Entrainment Between Webs and Rollers
• When Is Air Important Between Permeable Webs and Rollers/Wound Rolls?
• Some Practical Observations on Entrained Air
• Air Entrainment on Centerwinders
• An Introduction to Nip Rollers on Winders
• Modeling Air Exclusion by a Nip Roller
• Exhaust of Air Entrained From the Edges of a Wound Roll
• The Effect of Air Entrainment on Wound Roll Stresses
• Effect of Air Exhaust on Wound Roll Stresses
• Summary
• References

11. The Effects of Moisture and Temperature

• Time Constants for Movement of Moisture/Temperature in a Wound Roll
• Moisture/Temperature Profiles of a Wound Roll
• Thermoelastic Behavior in Wound Rolls
• Hygroscopic Behavior in Wound Rolls
• References

12. Viscoelastic Behavior

• Creep and Stress Relaxation
• Viscoelastic Behavior
• References

13. Defects Predicted by Winding Models

• Pressure Related Defects
• Bursts, Baggy Lanes, Ridges and Hardstreaks
• Modeling of Simple Slippage Related Defects
• Telescoping
• Crepe Wrinkles
• Starring
• Tin-Canning
• Core Collapse
• Loose Cores and Core Stiffness
• References

14. Dynamic Behavior at High Speeds

• Centrifugal Effects
• Vibration
• References

Section III—MEASUREMENT

15. Wound Roll Sampling and Inspection

• Why Measure?
• Measurement Methods
• Methodology
• Sampling
• Interchangeability of Measurements
• References

16. Measures of Roll Hardness

• Billy Club and its Variants
• RhoMeter and RhoHammer
• Backtender’s Friend
• Schmidt (Concrete) Hammer
• Parotester
• TAPIO RQP
• References

17. Measurements of Interlayer Pressure

• Pull Tab
• Smith Needle
• Core Torque
• Axial Press Test
• Pressure Transducers
• Caliper In-Roll
• Acoustic Time-of-Flight
• References

18. Measurements Based on Strain

• Cameron Gap
• J-Line
• Radially Drilled Holes
• Slit Roll Face
• Strain Gages
• WIT-WOT
• References

19. Density Based Measures

• Air In Roll
• Roll Density
• Density Analyzer—History
• Density Analyzer—Construction
• Density Analyzer—Theory of Operation
• Analysis of the Density Analyzer
• References

20. Other Wound Roll Measures

• Profile
• Bubbleometer
• X-Ray Tomography
• References

21. Wound Roll Measurement Considerations

• Is my Web Good?—Sampling Across the Width of the Roll
• Is my Roll or my Winder Good?—Sampling Through the Roll
• Is It the Winder’s Fault?
• Is my Measurement Good?—Testing the Test

Appendix A—Units and Conversions
Appendix B—Selected Bibliography
Appendix C—Selected Calculations
Appendix D—Glossary

Index

About the Authors