Three-dimensional 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 three-dimensional study in the area of polymer slitting is lacking. In this study, a three-dimensional model of the slitting process of the polymeric tape substrate is developed using the finite element method and the effect of various blade and web parameters on the quality of the edge is analyzed. A modification of a two-dimensional model developed earlier is used to compliment the three-dimensional study. The material of a typical substrate has been accurately modeled and a failure criterion incorporated to model the material separation. A criterion for comparison of the quality of slit edge is proposed. Parametric study of the effect of blade and web parameters has been conducted. Vertical engagement, edge radius, blade speed, blade radius, longitudinal tension in the web and web thickness are varied and their effect on edge quality is analyzed. An analytical model is developed to study the effect of blade and web parameters and a damage parameter relating edge quality to these parameters is proposed.