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As some companies in the paper industry struggle to shift from commodity grades to value added products, technical challenges and opportunities have grown tremendously. These new products require more stringent manufacturing specifications and improved performance relative to those of lignocellulosic fibers currently being produced. Hence, topochemical and mechanical modifications of pulp fibers have moved to the forefront of many corporate strategies. Researchers are beginning to develop new tools to help better understand the fundamental mechanisms of fiber modifications and how to most efficiently apply them. Two novel approaches are presented. First, a new method to observe single fiber crossings is developed. It was found that refining reduces the stepheight in the fiber crossing for both hardwood and softwood kraft pulps by increasing the tendency of the fibers to collapse, deform, and assume a lens like shape. The effect of pulp type, bleaching, drying, wet pressing, and fiber charge were also investigated. Graphs of stepheight versus freespan were linear through the origin suggesting that the freespan (flexibility) of the crossing fiber is largely unimportant to the formation of fiber crossings. Quite surprisingly, the ratio of stepheight to freespan remained relatively constant no matter the treatment. Only bleaching and the addition of surface charge via CMC had any independent impact on freespan. The data do not fit bending or shear mechanisms that have been developed in the literature suggesting that another mechanism may be responsible for the deformation behavior of single fiber crossings. Also, a method employing fluorescence microscopy and fluorescence resonance energy transfer is used to image the areas of a fiber-fiber interface while they were bonded. Analysis of the FRET signal from fiber crossings indicate that wet pressing increased the FRET occurring between the two dyed fiber surfaces. The results are consistent with the increased amount of interdiffusion expected with higher levels of wet pressing. Two novel techniques are used to investigate fundamental aspects of fiber deformation behavior and fiber-fiber bond formation. As these methods are further refined and utilized they will provide new avenues for researchers to explore and expand the property space of fibers and paper sheets.

Most of the water fed into a paper machine is removedmechanically in the forming and press sections. One of thefactor which has an important influence on mechanicaldewatering, i.e. in both forming and pressing, is thestress-strain behaviour of the fibre network. The focus of this thesis is on the development of improvedmathematical descriptions of the stress-strain behaviourexhibited by fibre networks in the forming and press sections.The first part of the thesis presents a physically based modelof the forming and densification of fibre mats in twin-wireformers. The model can calculate the ecect of the applicationof a varied load through the forming section. It was developedfrom mass and momentum balances of the fibre and liquid phases,the fibre mat stress-porosity relation and an expression forthe permeability as a function of the porosity. The fibre-matstress-porosity relation used is rate-independent and presentshysteresis. Simulations have been conducted to study theeffects of roll pressure, blade pulses, wire tension andbeating. The effect of sequential blade pressure pulses afterthe forming roll on the dewatering and the concentrationgradients could be characterised. The simulations alsoexhibited rewetting by expansion when the fibre mats left theforming roll. Increasing wire tension resulted in increaseddewatering, but the rate of increase diminished rapidly withincreasing tension. The simulation results also indicated thatbeating has a large influence on dewatering. The second part of the thesis presents two models of therate-dependent stress-strain behaviour of the fibre networkthat is observed in wet pressing. The first model was based onthe approach pioneered by Perzyna (1966) for strain-ratedependent plasticity and was quite satisfactory for calculatingthe stress-strain behaviour of the fibre network in singlepress nips. It was successfully applied for studyingdensification and dewatering in both normal wet pressing andhigh temperature wet pressing. However, the first model onlyincludes rate dependence in the compression phase of thecompressionexpansion cycle; the expansion phase is treated asbeing rate independent The second model of the stress-strain behaviour of the fibrenetwork treats both compression and expansion as being ratedependent, according to experimental observations. It is basedon the idea that the wet fibre web may be conceived as alayered network of restricted swelling gels. A swollen fibre isa restricted gel, the inner swelling pressure in a swollenfibre wall being balanced by the stresses in the fibre wallstructure. The observed rate dependence of wet webs in bothcompression and expansion phases was attributed to the flow ofwater out of and into the fibre walls. The second model gavepredictions that are in good agreement with results fromuniaxial experiments using pressure pulses of arbitrary shapefor both a single pulse and a sequence of pulses. It maytherefore be used as a general model for the rheologicalbehaviour of the wet fibre network in wet pressing, providedthe model parameters are estimated from experimental data withsmall experimental error. KEYWORDS:Paper, modelling, dewatering, forming, wetpressing, fibre network stress, rheology, hysteresis,intra-fibre water, compressibility, structural stress,stress-strain, restricted gels, swelling. / <p>QC 20161026</p>

<p>Most of the water fed into a paper machine is removedmechanically in the forming and press sections. One of thefactor which has an important influence on mechanicaldewatering, i.e. in both forming and pressing, is thestress-strain behaviour of the fibre network.</p><p>The focus of this thesis is on the development of improvedmathematical descriptions of the stress-strain behaviourexhibited by fibre networks in the forming and press sections.The first part of the thesis presents a physically based modelof the forming and densification of fibre mats in twin-wireformers. The model can calculate the ecect of the applicationof a varied load through the forming section. It was developedfrom mass and momentum balances of the fibre and liquid phases,the fibre mat stress-porosity relation and an expression forthe permeability as a function of the porosity. The fibre-matstress-porosity relation used is rate-independent and presentshysteresis. Simulations have been conducted to study theeffects of roll pressure, blade pulses, wire tension andbeating. The effect of sequential blade pressure pulses afterthe forming roll on the dewatering and the concentrationgradients could be characterised. The simulations alsoexhibited rewetting by expansion when the fibre mats left theforming roll. Increasing wire tension resulted in increaseddewatering, but the rate of increase diminished rapidly withincreasing tension. The simulation results also indicated thatbeating has a large influence on dewatering.</p><p>The second part of the thesis presents two models of therate-dependent stress-strain behaviour of the fibre networkthat is observed in wet pressing. The first model was based onthe approach pioneered by Perzyna (1966) for strain-ratedependent plasticity and was quite satisfactory for calculatingthe stress-strain behaviour of the fibre network in singlepress nips. It was successfully applied for studyingdensification and dewatering in both normal wet pressing andhigh temperature wet pressing. However, the first model onlyincludes rate dependence in the compression phase of thecompressionexpansion cycle; the expansion phase is treated asbeing rate independent</p><p>The second model of the stress-strain behaviour of the fibrenetwork treats both compression and expansion as being ratedependent, according to experimental observations. It is basedon the idea that the wet fibre web may be conceived as alayered network of restricted swelling gels. A swollen fibre isa restricted gel, the inner swelling pressure in a swollenfibre wall being balanced by the stresses in the fibre wallstructure. The observed rate dependence of wet webs in bothcompression and expansion phases was attributed to the flow ofwater out of and into the fibre walls. The second model gavepredictions that are in good agreement with results fromuniaxial experiments using pressure pulses of arbitrary shapefor both a single pulse and a sequence of pulses. It maytherefore be used as a general model for the rheologicalbehaviour of the wet fibre network in wet pressing, providedthe model parameters are estimated from experimental data withsmall experimental error.</p><p><b>KEYWORDS:</b>Paper, modelling, dewatering, forming, wetpressing, fibre network stress, rheology, hysteresis,intra-fibre water, compressibility, structural stress,stress-strain, restricted gels, swelling.</p>

For the analysis of the wet pressing process, which was presented in the first part of this paper, a theoretical approach was chosen. This enabled the pre-definition of three quality-related priorities which now will be considered in detail in the second part. For further analysis, real process data, recorded in an early phase of the process implementation, are used. The challenge is that in this process status, the availability of data is limited or the data sets are incomplete. Supported by the theoretical approach, an easier interpretation of the process data, and in case of ambiguous issues, an accelerated decision making is expected. The objective is to show that this combination is suitable for the process analysis in an early production phase.

The wet pressing process represents a new production method for carbon fibre-reinforced plastics components. Due to the low cycle times, it is suitable for use in the automotive industry. Therefore, a sufficient degree of industrialisation needs to be achieved, which is characterised by a stable process. The knowledge about relevant process parameters, their interactions, and influence on the part quality builds the basis of an economic process. This is a major challenge, since in the early stage of process development the available amount of recorded process data is small and the data sets are not complete. As the implementation of time-, material-, and cost-intensive experiments represents no acceptable alternative, a theoretical approach is chosen. This article describes a theoretical procedure to define the critical factors of the wet pressing process with significantly less resource input.

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