The cast film process is studied and a numerical simulation is performed using a finite element method. Two dimensional equations involving the thickness and a mean velocity are used by considering the film as a thin layer. The process is assumed to be isothermal between the die exit and the quick cooling on the chill roll. The width of the film is computed iteratively as a free surface problem by means of a finite element method. The thickness distribution of the film is obtained by a finite volume method. This approach allows modeling of the well known “dog‐bone” or “edge bead” defect with a reasonable computation time.
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