Rheological and Thermal Behavior of Calendering Process of Hybrid Nanofluid: A Magnetohydrodynamic Thin Film Analysis

The current investigation reports the rheological implications on thin film production with magnetized hybrid nanofluid during the calendering process. Hybrid nanofluids are reported to have better rheological characteristics, improved mechanism of heat transfer in liquid, viscosity modification, and thermal conductivity enhancement as related to the usual unitary nanofluid. Lubrication Approximation Theory (LAT) is applied to simplify the respective system of non‐dimensional equations and solved by employing analytical as well as numerical approaches to find velocity, temperature, pressure gradient, exiting film thickness, pressure, and other mechanical quantities. The graphical illustrations are thoroughly explained by providing physical reasoning for the obtained variations. Hybrid nanoparticle‐based molten polymer modifies the fluid viscosity, enhancing pressure gradient and temperature distribution. The relation between film attachment and detachment point also varies under hybrid nanoparticle volume fraction and Hartmann number. Engineering quantities like separating force and power input are enhanced due to hybrid nanoparticles because of higher fluid viscosity and pressure distribution, but an opposite trend is detected due to MHD. The current investigation focuses on the rheology and controlling factors for the heat transfer mechanism and film thickness, without extensive experimentation to save project cost and precious time. It also helps improve product performance and quality in industrial thin film applications.