Optimization and sensitivity analysis of heat transfer for Powell–Eyring fluid between rotating rolls with temperature-dependent viscosity: A mathematical modeling approach

This study explores the flow of a non-Newtonian fluid between two rolls that are counter-rotating at the same speed and of equal size. The fluid's viscosity depends on temperature, and we investigate its theoretical impact on the thickness of the sheet and other engineering parameters relevant to the process. We derive non-dimensional mass and momentum balance equations using suitable transformation and the lubrication approximation theory. The expressions for velocity distribution, pressure gradient, flow rate, temperature profile, and pressure fields have been obtained by utilizing the perturbation method. After obtaining these expressions, we compute engineering quantities such as the roll separation force, streamline, Nusselt number, and the power input required to drive both cylinders based on the system's kinematical and geometrical parameters. We also obtain numerical solutions using the finite difference method and built-in (BVP method) in Maple. Further, we use response surface methodology and analysis of variance to determine what the mathematical models mean and whether they are good enough for sensitivity and optimization analysis of the heat transmission and roll separation force. Using statistical tools such as the R2, we determine that our Nusselt number and roll separation force provide the best solution for the considered model. Additionally, it has been observed that as the Weissenberg number increases, velocity tends to rise; conversely, velocity decreases with a higher velocity ratio. Also, the temperature profile is notably influenced by the Brickman number and increases with the increase in the Brickman number. It has also been noted that as the values of velocities ratio increase, the separation points shift toward the nip region, while concurrently, the coating thickness decreases. Furthermore, we also demonstrate that compression between analytical and numerical solutions for the considered problem of fluid flow, which suggests that the results presented here are reasonable. Finally, we compare our work with published studies to validate our findings. Hence, these factors help in an efficient fluid coating process and improve the substrate life.