Modeling the effect of pigment morphology on the dynamic compression of coating layers using DEM

In the present paper, discrete element method (DEM) was employed to investigate the effect of pigment morphology on packing dynamics and compressive behavior of paper coating layers in calendering process. Spherical, platy, and needle-like particles, representing GCC, delaminated clay, and aragonite PCC pigments, were considered in this study. For each particle shape, the compression of coating structures formed by mono-sized and poly-dispersed pigments were modeled. Stress–strain behavior of the coating layers and in-plane and out-of-plane movements of the pigment particles during the compression were computed under the same maximum compressive stress. Simulation results revealed that the in-plane movements of the pigment particles during compression in the calender nip were small in magnitude (<0.35 μm). These findings help to better understand the smoothening phenomena of coating structures during the calendering process.