A Hybrid Numerical Approach for Convective Heat Transfer and Nonlinear Slip Analysis in the Blade Coating Process

Blade coating is a process used to provide a consistent liquid coating on a moving sheet, with significant applications in coated plastic industries, plastic polyvinyl chloride (PVC) fabrics, and paints. In this article, we studied the non‐isothermal analysis of the blade coating process with non‐linear slip effects at the blade surface. The material used to coating the substrate/web is characterized using the Yeleswarapu fluid model. The basic laws of fluid dynamics are implemented to modeled the 2D incompressible flow equations in the process of blade coating. The modeled equations are simplified with the help of normalized variables and the low Reynolds approximation theory. The simplified partial differential equations are solved numerically using a hybrid scheme, which is a combination of shooting and finite difference algorithms. The influence of the material parameters and slip coefficient on the engineering variables and flow characteristics are visualized with the help of various graphs and tables. The results reveal that the velocity of the coated substrate and coating thickness increase with increasing slip values compared to the Newtonian model. The temperature distribution rises with increasing Brinkman and Weissenberg numbers. The coating thickness decreases by 2.4% and the blade load increases by 49% relative to Newtonian values as the Weissenberg number increases.