On the Design of Corrugated Boards: A New FEM Modeling and Experimental Validation

TL;DR

This paper introduces a simplified FEM modeling approach for corrugated boards that combines homogenization and statistical correction factors, enabling faster and accurate structural simulations for large packaging structures.

Contribution

A new FEM modeling method for corrugated boards that incorporates homogenization and Weibull-based corrections for internal mechanisms, validated through experiments.

Findings

The proposed model reduces computational time significantly.

Statistical Weibull parameters effectively represent contact and buckling mechanisms.

Model validation confirms accuracy and efficiency for large structures.

Abstract

This study presents a simplified FEM modeling approach suitable for large structures made of corrugated boards, such as customized packages, based on a homogenization method, which is combined with correction factors for internal mechanisms. The homogenization process reduces computational time by transforming flute geometries into equivalent elastic models. In large deformations and in the presence of contact for a given geometry, the effective elastic modulus in the thickness direction, as well as the effective thickness of the structure, are corrected by two statistical Weibull distributions representing the contact and buckling mechanisms in a corrugated board. The Weibull parameters are obtained via experimental analysis, and such a process is then validated. The results demonstrate that the statistical parameters ($\beta_1 = 0.14$, $\beta_2 = 1.31$) can be used for the simplistic representation of corrugated boards, being computationally efficient. This research contributes to the optimization of corrugated packaging design, specifically by simplifying FEM models for faster yet equally accurate simulations.