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The coating thins invisibly, then a bare patch appears and yarn scorches on the next pass.
Remaining Coating Thickness
—µm
Left after mechanical and thermal wear to date
Wear Breakdown
Mechanical Wear
—µm
Thermal Cycling Wear
—µm
Total Wear
—µm
Pressure Acceleration
—×
Hours to Replacement
—h
Uniform wear across the cylinder is assumed and coatings do not fail uniformly — they fail at an edge, a repair, a thermal-gradient band or wherever the yarn sheet runs consistently, and one bare patch condemns the cylinder regardless of average thickness. Both rate constants must be recovered from measured coating thickness on cylinders taken out of service, since they depend on the coating system, the size recipe and how abrasive the yarn is. Sticking, scorching and size build-up are the practical end-of-life signals and generally appear before any thickness measurement is taken.
Using this calculator
About the Sizing Cylinder Non-Stick Coating Degradation Predictor
The formula
This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.
Each input feeds the expression evaluated in the browser; the symbol table below names every term and its unit.
Symbols used above
Symbol
Stands for
Unit
coatingThickness
Coating Thickness When New
µm
contactPressure
Yarn Contact Pressure
kPa
referencePressure
Reference Pressure
kPa
pressureExponent
Pressure Exponent
n
wearRate
Wear Rate at Reference
µm per 1000 h
operatingHours
Operating Hours
h
thermalCycles
Heat-up Cycles
no.
wearPerThousandCycles
Wear per 1000 Thermal Cycles
µm
failureThickness
Failure Thickness
µm
remainingThickness
Remaining Coating Thickness
µm
mechanicalWear
Mechanical Wear
µm
thermalWear
Thermal Cycling Wear
µm
totalWear
Total Wear
µm
pressureFactor
Pressure Acceleration
×
hoursToReplacement
Hours to Replacement
h
How the result is derived
Step by step, from the values you type to the figure on screen.
The 9 inputs are read from the form on every keystroke: Coating Thickness When New, Yarn Contact Pressure, Reference Pressure, Pressure Exponent, Wear Rate at Reference, Operating Hours, Heat-up Cycles, Wear per 1000 Thermal Cycles and Failure Thickness.
Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
The validated values are substituted into the expression above, which resolves Remaining Coating Thickness together with every supporting figure in one pass — no value is carried over from a previous entry.
The supporting outputs — Mechanical Wear, Thermal Cycling Wear, Total Wear, Pressure Acceleration and Hours to Replacement — come from the same pass, so they always describe the same case as the headline figure.
Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.
What each input means
Where to read each value on the floor, the unit it must be in, and the range the tool accepts.
Input
Unit
Accepted range
Default
What it means
Coating Thickness When New
µm
5 to 200 µm
25
Yarn Contact Pressure
kPa
1 to 200 kPa
18
Reference Pressure
kPa
1 to 200 kPa
15
Pressure Exponent
n
0.5 to 4 n
1.3
Wear Rate at Reference
µm per 1000 h
0.05 to 30 µm per 1000 h
1.8
Operating Hours
h
10 to 100000 h
6200
Heat-up Cycles
no.
0 to 20000 no.
480
Wear per 1000 Thermal Cycles
µm
0 to 20 µm
0.6
Failure Thickness
µm
0.5 to 50 µm
5
What the tool returns
The headline figure and every supporting value it is built from.
Output
Unit
What it tells you
Remaining Coating Thickness (headline result)
µm
Left after mechanical and thermal wear to date
Mechanical Wear
µm
Thermal Cycling Wear
µm
Total Wear
µm
Pressure Acceleration
×
Hours to Replacement
h
Worked example
Given
Coating Thickness When New
25 µm
Yarn Contact Pressure
18 kPa
Reference Pressure
15 kPa
Pressure Exponent
1.3 n
Wear Rate at Reference
1.8 µm per 1000 h
Operating Hours
6200 h
Heat-up Cycles
480 no.
Wear per 1000 Thermal Cycles
0.6 µm
Failure Thickness
5 µm
The tool loads with this case already solved — the Remaining Coating Thickness shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.
How to use it
Work through the input groups in order — Coating & Contact and Service & Thermal. The defaults are a realistic case, so you can change one value at a time and watch what moves.
There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
Read Remaining Coating Thickness in the dark results panel — that is the headline figure, expressed in µm.
Check the supporting rows underneath (Mechanical Wear, Thermal Cycling Wear, Total Wear, Pressure Acceleration and Hours to Replacement) before acting on the headline — they are where an implausible input usually shows itself first.
Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.
Where this is used
Process planning — establishing Remaining Coating Thickness before a trial is booked, so machine time and material in Predictive Maintenance & Spare Parts Physics are committed against a calculated figure rather than an estimate.
Costing and quotation — Remaining Coating Thickness is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Coating Thickness When New) shows how much of the gap in Remaining Coating Thickness each variable explains.
Teaching and study — the accepted ranges bracket normal Predictive Maintenance & Spare Parts Physics practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.
Assumptions and limits
Uniform wear across the cylinder is assumed and coatings do not fail uniformly — they fail at an edge, a repair, a thermal-gradient band or wherever the yarn sheet runs consistently, and one bare patch condemns the cylinder regardless of average thickness. Both rate constants must be recovered from measured coating thickness on cylinders taken out of service, since they depend on the coating system, the size recipe and how abrasive the yarn is. Sticking, scorching and size build-up are the practical end-of-life signals and generally appear before any thickness measurement is taken.
Every input is bounded to the range normal practice occupies (Coating Thickness When New 5 to 200 µm, Yarn Contact Pressure 1 to 200 kPa and Reference Pressure 1 to 200 kPa, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.
Questions people ask
What do I need to know before using the Sizing Cylinder Non-Stick Coating Degradation Predictor?
Have these to hand: Coating Thickness When New, Yarn Contact Pressure, Reference Pressure, Pressure Exponent, Wear Rate at Reference, Operating Hours, Heat-up Cycles, Wear per 1000 Thermal Cycles and Failure Thickness. With those entered, the tool returns Remaining Coating Thickness immediately.
What exactly is Remaining Coating Thickness?
Left after mechanical and thermal wear to date. It is reported in µm. It is derived from Coating Thickness When New, Yarn Contact Pressure, Reference Pressure, Pressure Exponent, Wear Rate at Reference, Operating Hours, Heat-up Cycles, Wear per 1000 Thermal Cycles and Failure Thickness, and is the figure the rest of the Predictive Maintenance & Spare Parts Physics calculation is built around.
Which units does this calculator expect?
Enter Coating Thickness When New in µm, Yarn Contact Pressure in kPa, Reference Pressure in kPa, Pressure Exponent in n, Wear Rate at Reference in µm per 1000 h, Operating Hours in h, Heat-up Cycles in no., Wear per 1000 Thermal Cycles in µm and Failure Thickness in µm. Mixing unit systems is the most common cause of a result that looks an order of magnitude wrong — convert before typing, not after reading.
What are the other figures under the main result?
They are the intermediate quantities the calculation passes through: Mechanical Wear, Thermal Cycling Wear, Total Wear, Pressure Acceleration and Hours to Replacement. They are shown because a headline number nobody can trace is a number nobody trusts — checking them against your own expectation is the fastest way to confirm the inputs were read as you intended.
Can I rely on this for a production decision?
Uniform wear across the cylinder is assumed and coatings do not fail uniformly — they fail at an edge, a repair, a thermal-gradient band or wherever the yarn sheet runs consistently, and one bare patch condemns the cylinder regardless of average thickness. Both rate constants must be recovered from measured coating thickness on cylinders taken out of service, since they depend on the coating system, the size recipe and how abrasive the yarn is. Sticking, scorching and size build-up are the practical end-of-life signals and generally appear before any thickness measurement is taken. Treat the output as an engineering estimate that narrows the trial window, not as a substitute for the trial.
