Finite element analysis of wire coating

A general‐purpose finite element program has been used to simulate the flow of polymers through wire‐coating dies. The analysis includes Newtonian and power‐law fluids. The effect of normal stresses was examined through a simple viscoelastic constitutive equation, Nonisothermal wire coating was studied to obtain the temperature field within the melt. The effect of a slip condition at the solid boundaries was also examined. The determination of the coating melt free surface was carried out through an iterative procedure. The finite element solution provides details about the existence and extent of recirculation regions, about hot spots due to viscous dissipation, and also captures the stress singularities present at the impact of the melt with the wire and at the exit from the die. Pressure distribution, maximum temperature rise, haul‐off wire tension, maximum wire tension, and stresses at the wire surface and die wall are also presented.