Discrete element method to predict coating failure mechanisms, TAPPI JOURNAL January 2018

ABSTRACT: The mechanical properties of coating layers are critical for post-application processes such as calendering, printing, and folding. Discrete element methods (DEM) have been used to simulate basic deformations such as tensile and compression, but have not been used as a tool to predict cracking-at-the-fold (CAF) or picking. DEM has the potential to increase our understanding of these failure mechanisms at the particle level. We propose a method to model the three-point bending of a coating layer and also the out-of-plane picking event during printing (using a z-direction scenario and an approach involving a moving force/velocity). Properties of the binder and the binder concentration are input parameters for the simulation. The model predicts the crack formation of the layer, the flexural modulus, and the maximum flexural strain during bending. The model also predicts the forces required for picking to occur. Results are compared with those of complimentary studies.

Application: Mills can use the findings of this study to better understand the mechanical properties of these coatings and to adjust coating formulations to better meet product needs.

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