Advanced simulation techniques for paperboard forming processes : a focus on thermoforming and paper cup bottom forming

Abstract

This thesis focuses on enhancing paper-based packaging processes through the development and application of advanced Finite Element Analysis (FEA) models to optimize thermoforming of paperboards by employing the Tsai-Wu failure criteria and bottom forming of paper cups. The research focuses on refining simulation techniques to predict and control the behavior of paper materials under various manufacturing conditions, significantly improving process efficiency and product integrity. The study has revealed that a careful adjustment of the material properties and process parameters based on the results from the simulation can bring significant improvements to both durability and manufacturability of the final paperboard products. These advancements can serve to provide a methodological framework for other biodegradable materials reducing waste and saving energy consumption. Integration of such simulation models with Industry 4.0 technologies will potentially develop real-time manufacturing analytics and optimize processing efficiencies. This work contributes significantly to material science and practical manufacturing applications, as advanced simulation tools can indeed lead to improving quality and productivity for paper packaging production.