Determination of the Nip Angle in Roller Compactors With Serrated Rolls

In roller compaction, the nip angle defines the critical transition interface between the slip and nip regions which is used to model material densification behavior and the properties of compacted ribbons. Current methods to determine the nip angle require either sophisticated instrumentation on smooth rolls or input parameters that are difficult to obtain experimentally. In this study, a practical method to determine nip angles for serrated rolls was developed based on mass balance considerations established around the nip region. Experimental input relating to roll geometry, powder density, and mass output from the compactor were required and they could be obtained reliably. The calculated nip angles were validated against those obtained from physical measurements during actual roll compaction. These nip angles were in agreement for various powder formulations containing plastic and brittle materials. The nip angles ranged from 4° to 12° and decreased significantly when the proportion of brittle material increased. Nip angles were also calculated using the widely used Johanson model. However, wall friction measurement on serrated roll surfaces could be impractical. The Johanson model-derived nip angles could differ by 3°-8° just by altering the roughness of the reference wall and this had compromised their reliability.