The document discusses creating an accurate finite element model of paper cartons to replace physical testing. It involves creating the finite element model, conducting physical testing for validation, simulating loads, and validating results. Material properties are tested and used to refine the finite element model. Simulation results are compared to physical testing which show good agreement within 10% for force and 4mm for peak displacement. The finite element model is found to be reliable with potential for improving the modeling of creasing phenomena.

1. Geetha
Jagadeesan
Janet Amely
College of Engineering Guindy

2.  Replacement of physical testing of paper
cartons in industry with a database
 Creationof accurate Finite Element Model
of paper cartons

3.  Investment on physical testing
 Time
 Optimization
 Help SSI’s and Startups
 Paper cartons dominate packaging market

4. CARTON DATABASE
VALIDATED SIMULATION
FINITE ELEMENT MODEL

5.  Creation of finite element model of paper
cartons
 Physicaltesting of cartons for the purpose of
validation
 Simulation of loads
 validation

6. Material testing Simulation
Finite Element Model
force(N)
physical
200 simulation
150
100
Material Properties 50
Validation
displacement(mm)
2 4 6 8 10 12 14 16
Carton Testing

7. Box Compression Strength
Improvement of Pulp board 220 GSM, 350 GSM
Finite Element Model Box dimensions
 Ambient conditions
Tuck-in carton
Comparison of simulation and Physical testing of material
physical testing Physical testing of carton
Finite Element model
Simulation

9.  Grain direction
 Machine and cross direction
 Orthotropic

10.  Geometry
 Thickness
 Young’s modulus
 Shear modulus
 Poisson’s ratio

11.  Paperboard selection
• Pulp board with similar properties on both sides
 Paperboard conditioning
• Temperature :27+/-1 ̊ C
• Relative humidity :65+/-2%

13. Grammage Dimensions Thickness Tensile Young’s modulus
and (mm) strength (N/mm2)
Direction (N/mm2)
220 GSM L=180mm 0.238 26.62 334.47
Machine W=25mm
direction
220 GSM L=180mm 0.238 15.18 144.75
Cross W=25mm
direction
350GSM L=180mm 0.375 30.11 345.95
Machine W=25mm
direction
350GSM L=180mm 0.375 17.79 167.27
Cross W=25mm
direction

14. 350 GSM Machine Direction
Stress (kgf/cm²)
300 Break
Greatest Slope
200
100
Preload
00
0.0 5.0 10.0 15.0 20.0
Percentage Strain
350 GSM Cross Direction
Stress (kgf/cm²)
200
Break
150
Greatest Slope
100
50
0
0.0 5.0 10.0 15.0 20.0 25.0
Percentage Strain

16. • Geometric model
• Finite Element Model
• Analysis
• Postprocessing
• Refining Results

26. MESH SIZE (mm) FORCE (N)
12.3 0.7542
6.15 1.2057
3.075 1.2060

27. • Carton design :Glued
• Dimension : 85mm * 125mm * 246mm

28. Grammage and Compressive Strength Load at Limit Stress at limit
direction (N)
(N/mm2) (N/mm2)
220 GSM Machine 0.00519 41.10 0.00392
direction
220GSM cross 0.00421 26.38 0.0240
direction
350GSMMachine 0.0254 168.92 0.0158
direction
350GSMcross 0.0223 163.53 0.0153
direction

30. y
simulation
200 physical testing
150
Force (N)
100
50
x
2 4 6 8 10 12 14 16 18
displacement(mm)

31. force(N)
physical
200 simulation
150
100
50
displacement(mm)
2 4 6 8 10 12 14 16
• 10% force deviation
• 4mm peak deviation

32. force(N)
physical
200 simulation
150
100
50
displacement(mm)
2 4 6 8 10 12 14 16

33.  Simulation reliable
 Scope
for improvement- creasing
phenomenon