Search Results (5)

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. Full article

The discrete element method (DEM) has become the numerical method of choice for analysing and predicting the behaviour of granular materials in bulk handling systems. Wet-and-sticky materials (WSM) are especially problematic, resulting in build-up and blockages. Furthermore, due to the large number of particles in industrial-scale applications, it is essential to decrease the number of particles in the model by increasing their size (upscaling or coarse graining). In this study, the accuracy with which upscaled DEM particles can model the discharge of a cohesive material from a belt conveyor onto an inclined impact plate was investigated. Experimentally, three sand grades (particle size distributions, PSDs) were used, each in a dry (non-cohesive) state and with three levels of moisture-induced cohesion. The effects of the modelled PSDs on the material flow, build-up on the plate, the peak impact force and the residual weight were investigated. Although a linear cohesion contact model was mostly used, the results were also compared to that of the Johnson–Kendall–Roberts (JKR) and simplified JKR (SJKR) models. It was found that the general profile of the pile (build-up) could be accurately modelled, but using a more accurate (but still upscaled) PSD improved the results. The impact force and the residual weight on the plate could be accurately modelled (error $<15\%$) if the particle size was not excessively scaled. The maximum acceptable scaling factor was found to be a geometric factor of the bulk measure of interest, and not a factor of the physical particle size. Furthermore, with an increase in cohesion, the bulk measures such as the thickness of the discharge stream and the height of the material build-up increased, which meant that the maximum acceptable scale factor also increased. The results are valuable for future accurate and efficient modelling of large industrial scale applications of WSMs. Full article

Corrugated paperboard is a sandwich structure composed of wavy paper (fluting) bonded between two flat paper sheets (liners). The analysis of an entire package using three-dimensional numerical finite element models is computationally expensive due to the waved geometry of the board that requires the use of a relatively large number of elements in a simulation. Because of this, homogenisation approaches are used to evaluate equivalent homogenous models with similar material properties. These techniques have been successfully implemented by various researchers to evaluate the strength of corrugated paperboard. However, studies analysing the various homogenisation techniques and their ranges of applicability are limited. This study analyses the application of three homogenisation techniques: classical laminate plate theory, first-order shear deformation theory and deformation energy equivalence method in the evaluation of effective elastic material properties. In addition, inverse analysis has been applied to determine the effective properties of the board. Finite element models have been used to evaluate the accuracy of the three homogenisation techniques in comparison to the inverse method in modelling four-point bending tests and the results reported. Full article

Granular materials are abundant in nature, and in most industries, either the initial constituents or final products are in granular form during a production or processing stage. Industrial processes and equipment for the handling of bulk solids can only be improved if we can understand, model and predict the material behaviour. The discrete element method (DEM) is a numerical tool well-suited for this purpose and has been used by researchers and engineers to analyse various industrial applications and processes. However, before any bulk scale modelling can be undertaken, the input parameters must be carefully calibrated to obtain accurate results. The calibration of parameter values for non-cohesive materials has reached a level of maturity; however, the calibration of cohesive materials requires more research. This paper details the most prevalent contact models used to model cohesive materials—presented in a consistent notation. Moreover, the significant differences between the models are highlighted to provide a reference for engineers and researchers to select the most appropriate model for a specific application. Finally, a critical review of calibration experiments and methodologies often used for cohesive materials is also presented. This provides a solid basis for DEM practitioners to select the most appropriate calibration methodology for their application and for researchers to extend the current state-of-the-art practices. Full article

Finite element analysis (FEA) has been proven as a useful design tool to model corrugated paperboard boxes, and is capable of accurately predicting load capacity. The in-plane deformation, however, is usually significantly underpredicted. To investigate this discrepancy, a panel compression test jig, that implemented simply supported boundary conditions, was built to test individual panels. The panels were then modelled using non-linear FEA with a linear material model. The results show that the in-plane deformation was still underpredicted, but a general improvement was seen. Three discrepancies were identified. The first was that the panels showed an initial region of low stiffness that was not present in the FEA results. This was attributed to imperfections in the panels and jig. Secondly, the experimental results reported a lower stiffness than the FEA. Applying an initial imperfection in the shape of the first buckling mode shape was found to reduce the FEA stiffness. Thirdly, the panels showed a decrease in stiffness near failure, which was not seen in the FEA. A bi-linear material model was investigated and holds the potential to improve the results. Box compression tests were performed on a Regular Slotted Container (RSC) with the same dimensions as the tested panel. The box displaced 13.1 mm compared to 3.5 mm for the panel. There was an initial region of low stiffness, which accounted for 7 mm of displacement compared to 0.5 mm for the panels. Thus, box complexities such as horizontal creases should be included in finite element (FE) models to accurately predict the in-plane deformation, while a bi-linear (or any other non-linear) material model may be useful for panel compression. Full article