Finite element analysis of the magnetic tape slitting process

The quality of factory-slit tape edges plays an important role in determining the performance of tape drives and is a controlling factor for data track density. A theoretical study of the slitting process and parameters involved could assist greatly in the optimization of the process and development of better quality slit edges. Various finite element studies exist in the area of sheet metal blanking and cutting but a similar study in the area of polymer slitting is lacking. In this study, the slitting process of the tape substrate is modeled using the finite element method and the effect of various blade and web parameters on the quality of the edge is analyzed. The material of a typical substrate has been accurately modeled and a failure criterion incorporated to model the material separation. A criterion for goodness of the edge is proposed. Parametric study of the effect of blade and web parameters has been conducted. Horizontal clearance, blade angle, edge radius and tape thickness are varied and their effect on edge quality is analyzed. Edge profiles are generated for different values of the critical damage value using the failure criterion. Finally, two pairs of blades are modeled separated by a tape width and it is shown that the stress distributions at the two edges of the tape are different.