Finite-element simulation with a homogenization model and experimental study of free drop tests of corrugated cardboard packaging

Abdelkader Djilali Hammou,Boussad Abbès,Pham Tuong Minh Duong,Ying-Qiao Guo,Mohammed Makhlouf

doi:10.1051/meca/2012013

Abstract

This paper presents experimental and numerical studies of drop tests of corrugated cardboard packaging containing different foam cushions. An efficient homogenization model for the corrugated cardboard has been developed. In our homogenized model, the corrugated cardboard is represented by a 2D plate. Instead of using a local constitutive law (relating the strains to the stresses) at each material point, the homogenization gives the global rigidities (relating the generalized strains to the resultant forces) for the equivalent homogeneous plate. This model was implemented into the FE software ABAQUS. The foam behaviour was experimentally determined and modelled using a crushable foam model of ABAQUS. The packages are tested in free fall from a given height on a rigid floor. The deceleration of the packed product was recorded using a triaxial accelerometer. The numerical results obtained using the FE simulation with the homogenized model agree well with the experimental results. We have also shown that the contribution of the corrugated cardboard box to the shock response could not be neglected in the design of cushioning package.

Highlights

IntroductionProducts can accidentally fall onto the floor causing some damages on the products
During storage and transportation, products can accidentally fall onto the floor causing some damages on the products
2.1 Corrugated cardboard box Several corrugated cardboard boxes with their inside dimensions of 150 × 150 × 90 mm3 and 4 mm thickness are used for the experimental drop tests (Fig. 1)

Summary

Introduction

Products can accidentally fall onto the floor causing some damages on the products. The corrugated cardboard packages and the foam cushions are designed to protect the product from the shock it may undergo. As the product design always tends towards light, a high impact performance becomes extremely important for product design issues [1,2]. A product reliability test to prevent impactinduced damage is carried out by a procedure of “design – prototype – test – redesign” which is highly cost and time consuming. A numerical modelling of the product and its packaging provides an efficient methodology to predict the structural strength during impact. The finite-element simulation allows to avoid numerous experimental tests and to predict possible failures during the design stage

Methods

Results

Conclusion