In the Roll-to-Roll (R2R) system, the design and development for a roller path and control system are mainly performed by the expert’s experience. There are some important issues in the numerical analysis method of R2R system. This study proposes an efficient R2R system analysis method. The first one is the Approximated Winding Length Estimation (AWLE) algorithm which can calculate the analytic winded length of the workpiece. The core winder is approximated with line and arc segments in this algorithm. As a result, in the numerical model of R2R system, we can replace the winder characteristics with the approximated winding length estimation (AWLE) algorithm. The second one is the contact algorithm between workpiece and rollers. This contact algorithm must be stable and fast for precise analysis. The third one is the flexible workpiece model. The workpiece can be modeled by the finite elements. By implementing these some important issues, this paper proposes an efficient R2R system analysis method.

An analysis for operating characteristics of journal bearing lubrication system is performed based on the numerical model. Dynamic bearing lubrication characteristics such as oil film pressure and thickness distribution can be analyzed through a numerical model with an integration of elastohydrodynamics and multi-flexible-body dynamics (MFBD). In particular, the oil film thickness variation by elastic deformation is considered in the elastohydrodynamic analysis by applying the bending stiffness effect of journal. And the oil film thickness variation by the bending stiffness effect is applied to the fluid governing equations to calculate the oil film pressure in the elastohydrodynamic lubrication region. A series of process proposed in this study is available for the analysis of realistic elastohydrodynamic lubrication phenomenon. Also, a numerical example for the journal bearing lubrication system is demonstrated and compared with the experimental results. The numerical results considering the bending stiffness effect show a good agreement with the experimental results.

An analysis for operating characteristics of piston lubrication system is performed based on the numerical model in this study. Dynamic piston lubrication characteristics such as oil film pressure and thickness distribution can be analyzed through a numerical model with an integration of elastohydrodynamics and multi-flexible-body dynamics (MFBD). In particular, the oil film thickness variation by elastic deformation is considered in the elastohydrodynamic analysis by using the modal reduction method in MFBD system. And this effect is reflected on the fluid governing equations to evaluate the oil film pressure in the lubrication region. A series of process proposed in this study is available for the analysis of realistic elastohydrodynamic lubrication phenomenon. A numerical example for the piston lubrication system is also demonstrated.