Geetha

Jagadeesan

Janet Amely

College of Engineering Guindy

Replacement of physical testing of paper

cartons in industry with a database

Creation of accurate Finite Element Model

of paper cartons

Investment on physical testing

Time

Optimization

Help SSI’s and Startups

Paper cartons dominate packaging market

CARTON DATABASE

VALIDATED SIMULATION

FINITE ELEMENT MODEL

Creation of finite element model of paper

cartons

Physical testing of cartons for the purpose of

validation

Simulation of loads

validation

Material Properties

physical

simulation

2 4 6 8 10 12 14 16

50

100

150

200

displacement(mm)

force(N)

Material testingFinite Element Model

Simulation

Validation

Carton Testing

Box Compression Strength

Pulp board 220 GSM, 350 GSM

Box dimensions

Ambient conditions

Tuck-in carton

Physical testing of material

Physical testing of carton

Finite Element model

Simulation

Comparison of simulation and

physical testing

Improvement of

Finite Element Model

Grain direction

Machine and cross direction

Orthotropic

Geometry

Thickness

Young’s modulus

Shear modulus

Poisson’s ratio

Paperboard selection

• Pulp board with similar properties on both sides

Paperboard conditioning

• Temperature :27+/-1 ̊ C

• Relative humidity :65+/-2%

Grammage

and

Direction

Dimensions Thickness

(mm)

Tensile

strength

(N/mm2)

Young’s modulus

(N/mm2)

220 GSM

Machine

direction

L=180mm

W=25mm

0.238 26.62 334.47

220 GSM

Cross

direction

L=180mm

W=25mm

0.238 15.18 144.75

350GSM

Machine

direction

L=180mm

W=25mm

0.375 30.11 345.95

350GSM

Cross

direction

L=180mm

W=25mm

0.375 17.79 167.27

Stress (kgf/cm²)

00

100

200

300

Percentage Strain0.0 5.0 10.0 15.0 20.0

Break

Greatest Slope

Preload

General Purpose Pull to Break Setup

Preload:

Speed:

Gauge Length:

Area:

Break:

1.00 N

10.0 mm/min

About 120.0 mm

About 25.1 mm x 0.360 mm

Load drops quickly

350 GSM-MD

Stress (kgf/cm²)

0

50

100

150

200

Percentage Strain0.0 5.0 10.0 15.0 20.0 25.0

Break

Greatest Slope

General Purpose Pull to Break Setup

Preload:

Speed:

Gauge Length:

Area:

Break:

Not Applicable

20.0 mm/min

About 120.0 mm

About 25.1 mm x 0.360 mm

Load drops quickly

350 GSM-CD

350 GSM Machine Direction

350 GSM Cross Direction

• Geometric model

• Finite Element Model

• Analysis

• Postprocessing

• Refining Results

MESH SIZE (mm) FORCE (N)

12.3 0.7542

6.15 1.2057

3.075 1.2060

• Carton design :Glued

• Dimension : 85mm * 125mm * 246mm

Grammage and

direction

Compressive Strength

(N/mm2)

Load at Limit

(N)

Stress at limit

(N/mm2)

220 GSM Machine

direction

0.00519 41.10 0.00392

220GSM cross

direction

0.00421 26.38 0.0240

350GSMMachine

direction

0.0254 168.92 0.0158

350GSMcross

direction

0.0223 163.53 0.0153

simulation

physical testing

2 4 6 8 10 12 14 16 18

50

100

150

200

x

y

displacement(mm)

Force (N)

physical

simulation

2 4 6 8 10 12 14 16

50

100

150

200

displacement(mm)

force(N)

• 10% force deviation

• 4mm peak deviation

physical

simulation

2 4 6 8 10 12 14 16

50

100

150

200

displacement(mm)

force(N)

Simulation reliable

Scope for improvement- creasing

phenomenon