Abstract
Coating process is an important step in the manufacturing of different products, such as paper, adhesive and magnetic tapes, photographic films, and many other. The tensioned web roll coating is one the several methods used by different industries. It relies on the elastohydrodynamic action between the fluid and the tensioned substrate for transferring and applying the liquid. The main advantage of this method is its ability to apply very thin liquid layers with less sensitivity to mechanical tolerance at relative small cost. Despite its industrial application, theoretical analysis and fundamental understanding of the process are limited. This work analyses this elastohydrodynamic action by solving the differential equations that govern the liquid flow, described by the Navier–Stokes equation, and the web deformation, modelled by the cylindrical shell approximation. The goal is to determine the operating conditions at which the process is two dimensional and defect free. The equations are discretized by the Galerkin/finite‐element method. The resulting non‐linear system of equations is solved by Newton's method coupled with pseudo‐arc‐length continuation in order to obtain solutions around turning points. The theoretical results are used to construct an operating window of the process that is in agreement with limited experimental data. Copyright © 2003 John Wiley & Sons, Ltd.