CALENDERING

MAIN FUNCTION OF CALENDER

1. 2. 3. 4. SHEETING OF RUBBER COMPOUND-VARIOUS LENGTH&THICKNESS. SKIM COATING OF FABRICS. FRICTIONING OF FABRIC-SINGLE, DOUBLE COATING FABRICS ON BOTH SIDES. CONSTRUCTION OF A CALENDER 1.
A CALENDER CONSITS OF TWO OR MORE OPPOSITELY MOVING ROLLS (KNOWN AS BOWL) GENERALLY PLACED HORIZONTALLY ONE ABOVE THE OTHER. IT IS FITTED IN A PAIR OF VERTICAL IRON FRAMES STANDING ON A BASE PLATE AND CONNECTED BY A BRIDGE PIECE ABOVE THE TOP ROLL. THE ROLLS ROTATE TO PRODUCE SHEETING BY ADJUSTING THE DISTANCE APART (NIP) DIFFERENT GAUGES OF SHEETING BECOMES POSSIBLE.

2. 3.

4. 5.

IN RUBBER INDUSTRIES NORMALLY 3 OR 4 BOWLS ARE USED AND OCCASIONALLY FOR ROUGH GAUGES 2 ROLL CALENDER USED. FOUR ROLL CALENDERS CAN HAVE VERTICAL OR INVERTED L OR Z CONFIGURATION OF THE ROLLS.

6.

THE INVERTED L AND Z!CONFIGURATION ARE USED MAINLY FOR COATING FABRIC ON BOTH SIDES AT ONCE.

2.

CALENDER ROLLS
MADE OF BEST "UALITY CAST IRON CHILLED ON THE SURFACE TO A DIPTH OF #$ THE WORKING FACES OF THE ROLL ARE PRECISION GROUND AND POLISHED TO HIGH LUSTRE. THE ROLLS ARE MACHINED INTERNALLY TO EVEN WALL THICKNESS TO ENSURE UNIFORM HEATING AND COOLING FOR SATISFACTORY TEMPERATURE CONTROL.

ROLL BENDING (CAMBERING) GAUGE CONTROL

TO HAVE A UNIFORM THICKNESS OF SHUT ON A CALENDER IS A TOUGH JALE AS THE ROLLS ARE SUBJECT TO DEFLECTION. WHEN LOADED WITH PRE WARMED RUBBER COMPOUND THE HEAVY PRESSURE E%ERTED BETWEEN THE NIPS OF THE ROLLS CAUSES FURTHER DIFLECTION.

3 SO TO OVER COME THE PROBLEM OF THICKNESS VARIATION ACROSS THE WIDTH IS BY MAKING THE ROLLS A LITTLE THICKER IN THE MIDDLE BE A FEW THOUSANDS COMPARED TO THE ENDS AND THIS CALL AS &CAMBERING'.

SAFETY ( BRAKING SYSTEM

A CALENDER IS PROVIDED WITH NIP GUARDS OF THE MAN AND LOOP TYPES. THE BRAKING SYSTEM SHOULD BE ABLE TO STOP THE ROLLS IMMEDIATELY IN THE EVENT OF EMERGENCY. THIS IS DONE BY A SOLENOID OPERATED FRICTION BRAKE AND MAGNETIC CLUTCH WITH SAFETY WIRE.

MOST IMPORTANT FACTORS IN CALENDERING

THE ROLL SPEED THE ROLL TEMPERATURES THE FRICTION RATIO ACCURACY IN ROLL SETTING FOR CORRECT GAUGE.

HOWEVER* THE SUCCESS OF CALENDERING ALSO DEPENDS UPON VARIOUS OTHER FACTORS* SUCH AS VISCOSITY OF MATERIAL* THICKNESS OF SHEET DESIRED. SPEED OF ROLLS* DIMENSIONS OF ROLLS* ROLL CONTOURS* TEMPERATURE OF FEED STOCK AND EVEN FEEDING. COMMON SPEED FOR SHEETING + ,- METERS PER . MINUTES FOR COATED FABRICS + )- METERS PER . MINUTES.

COMPOUND CHARACTERISTICS FOR CALENDERING

A B C D FREE FROM E%CESSIVE SHRINKAGE MUST NOT STICK TO ROLL AT CALENDERING MUST POSSESS SUFFICIENT TACK FOR SUBSE"UENT BUILDING OPERATION OR ADHESIVE TO THE FAVRICS SCORCH FREE

00 COMMON PROBLEMS ( MEASURES FOR CALENDERING OPERATION. PROBLEMS CUSES PROCESSING APPROACHES COMPOUNDING APPROACHES

SHRINKAGE

RECOVERY OF ELASTIC NERVES

REDUCE PLASTICITY HIGHER ROLL TEMP HIGHER FEED STOCK.

INCREASES PLASTICISER THERMOPLASTIC RESINS.

BLISTER .AIR PROSITY

(1) INCREASE TEMP. OF (1) INCREASE FILLER FEED STOCK (2) LARGE PARTICLE (2) MINIMISE BANK SIZE FILLER (3) CROSS SECTIONAL AREA (3) ADD* OR INCEASE OF FEED STOCK ST. ACID* WA%ES. (4) USE LARGER DIAM. ROLL (INCREASED SURFACE) INSUFFICIENT 0. HIGHER ROLL TEMP PLASTICITY 2. HIGHER FEED STOCK TEMP.

ABNORMAL SURFACE (CROW'S FEET)

CALENDER GRAIN

DIFFERENT SHRINKAGE 0. NO LARGE TEMP. 0. INCREASES FILLER LENGTH WIDTH 2. LIMIT CALENDERING PLASTICISER DIRECTION. EFFECT (TWO ROLLS) 2.AVOID NISOTROPIC 3. SLOWER COOLING FILLER(CLAY TALC) 4. REDUCE CALENDER SPEED ROLL TEMP.DEPENDENCY 0.CHANGE ROLL TEMP. 0.INCREASESFILLER. WHITE FILLER TENDS TO AT WHICH A CALENDER PLASTICISER CAUSE IT. SHEET WILL COME. RATIO. LARGER PARTICLE FILLER

STICKING TO ROLLS