Numerical Modelling of Corrugated Paperboard Boxes

Abstract

Numerical modelling of corrugated paperboard is quite challenging due to its waved geometry and material non-linearity which is affected by the material properties of the individual paper sheets. Because of the complex geometry and material behaviour of the board, there is still scope to enhance the accuracy of current modelling techniques as well as gain a better understanding of the structural performance of corrugated paperboard packaging for improved packaging design. In this study, four-point bending tests were carried out to determine the bending stiffness of un-creased samples in the machine direction (MD) and cross direction (CD). Bending tests were also carried out on creased samples with the fluting oriented in the CD with the crease at the centre. Inverse analysis was applied using the results from the bending tests to determine the material properties that accurately predict the bending stiffness of the horizontal creases, vertical creases, and panels of a box under compression loading. The finite element model of the box was divided into three sections, the horizontal creases, vertical creases, and the box panels. Each of these sections is described using different material properties. The box edges/corners are described using the optimal material properties from bending and compression tests conducted on creased samples, while the box panels are described using the optimal material properties obtained from four-point bending tests conducted on samples without creases. A homogenised finite element (FE) model of a box was simulated using the obtained material properties and validated using experimental results. The developed FE model accurately predicted the failure load of a corrugated paperboard box under compression with a variation of 0.1% when compared to the experimental results.