Mathematical Modeling
Vol. 9 (2025), Issue 2, pg(s) 62-66

MATHEMATICAL MODELLING OF TECHNOLOGICAL PROCESSES AND SYSTEMS

FEA-Driven Design of Nonwoven Winder Drums: Stress Minimization and Rigidity Assessment for Structural Integrity

  • 1 KANSAN R&D Center, Izmir, Turkiye
  • 2 KANSAN R&D Center, Izmir, Turkiye; Ege University, Department of Mechanical Engineering, Izmir, Turkiye

Abstract

Nonwoven winding machines are critical equipment where the structural integrity of the main drum directly impacts the quality and stability of the final product. This study presents the mechanical analysis and braking system design for a main winding drum (Diameter 400 mm) in a high-speed nonwoven application, driven by Finite Element Analysis (FEA) for stress minimization. The load analysis, based on the Principles of Static Equilibrium, determined the total maximum load on the drum supports, considering a maximum spool weight of 1500 kg and a nip force of 1962 N. The resultant total load applied on the supports was calculated as approximately 11.5 kN. The FEA, utilizing ST37 steel, revealed a maximum Von Mises Stress of 1.754 MPa and an extremely low maximum deflection of 0.005 mm. This confirms an optimal factor of safety (FS approx 134) and high rigidity. Furthermore, the paper addresses the safety requirement for emergency stopping from a maximum speed (omega = 50 rad/s). The minimum required braking torque was calculated as 235 Nm, while the selected COREMO PNEUMATIC CALIPER BRAKE B-2N system provides 306.8 Nm, ensuring reliable and controlled deceleration. The results validate the structural and functional design, contributing to enhanced machine performance and operational safety.

Keywords

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