As long as the non-contact digital printing is not a common standard in the corrugated packaging industry, corrugated board crushing is a real issue that affects the load capacity of the boxes. Crushing mainly occurs during the converting of corrugated board (e.g. analog flexographic printing or laminating) and is a process that cannot be avoided. However, as show in this study, it can be controlled. In this work, extended laboratory tests were carried out on the crushing of double-walled corrugated board. The influence of fully controlled crushing (with a precision: ±10 μm) in the range from 10 to 70 % on different laboratory measurements was checked. Most of the typical mechanical tests were performed e.g. edge crush test, four-point bending test, shear stiffness test, torsional stiffness test, etc. on reference and crushed specimens. The residual thickness reduction of the crushed samples was also controlled. All empirical observations and performed measurements were the basis for building an analytical model of crushed corrugated board. The proven and verified model was then used to study the crushing effect of the selected corrugated board on the efficiency of simple packages with various dimensions.

The need for quick and easy deflection calculations of various prefabricated slabs causes that simplified procedures and numerical tools are used more and more often. Modelling of full 3D finite element (FE) geometry of such plates is not only uneconomical but often requires the use of complex software and advanced numerical knowledge. Therefore, numerical homogenization is an excellent tool, which can be easily employed to simplify a model, especially when accurate modelling is not necessary. Homogenization allows for simplifying a computational model and replacing a complicated composite structure with a homogeneous plate. Here, a numerical homogenization method based on strain energy equivalence is derived. Using the method proposed, the structure of the prefabricated concrete slabs reinforced with steel spatial trusses is homogenized to a single plate element with an effective stiffness. There is a complete equivalence between the full 3D FE model built with solid elements combined with truss structural elements and the simplified homogenized plate FE model. The method allows for the correct homogenization of any complex composite structures made of both solid and structural elements, without the need to perform advanced numerical analyses. The only requirement is a correctly formulated stiffness matrix of a representative volume element (RVE) and appropriate formulation of the transformation between kinematic constrains on RVE boundary and generalized strains.

The non-linear analysis of hollow-core concrete slabs requires the use of advanced numerical techniques, proper constitutive models both for concrete and steel as well as particular computational skills. If prestressing, cracking, crack opening, material softening, etc. are also to be taken into account, then the computational task can far exceed the capabilities of an ordinary engineer. In order for the calculations to be carried out in a traditional design office, simplified calculation methods are needed. Preferably based on the linear finite element (FE) method with a simple approach that takes into account material nonlinearities. In this paper the simplified analysis of hollow-core slabs based on the generalized nonlinear constitutive law is presented. In the proposed method a simple decomposition of the traditional iterative linear finite element analysis and the non-linear algebraic analysis of the plate cross-section is used. Through independent analysis of the plate cross-section in different deformation states, a degraded plate stiffness can be obtained, which allows iterative update of displacements and rotations in the nodes of the FE model. Which in turn allows to update the deformation state and then correct translations and rotations in the nodes again. The results obtained from the full detailed 3D nonlinear FEM model and from the proposed approach are compared for different slab cross-sections. The obtained results from both models are consistent.

In the paper, a modified nonlinear finite element method for analysis of trapezoidal plates geometrically reduced to shallow-shell Reissner-Mindlin formulation is presented. Due to the method proposed the complex plate cross-section and nonlinear materials may be modelled and no implementation of advanced constitutive law via user subroutines is needed. The generalized nonlinear constitutive law is used to update the stiffness of the plate element. The method enables modeling of complicated cross-sections, such as steel trapezoidal sheets, metal facing sandwich panels or reinforced concrete. Additionally, for those geometrically complex sections an advanced nonlinear material may be adopted. To verify the proposed method, a selected trapezoidal sheets were modeled in a commercial software as full 3D shell structures. By comparing displacements and forces, it was shown that both models behave almost identically, however, the simplified model has about 300-400 times less degrees of freedom, thus it is much more efficient.

In engineering practice, one can often encounter issues related to optimization where the goal is to minimize material consumption, minimize stresses or deflections of the structure. In most cases, these issues are addressed with finite element analysis software and simple optimization algorithms. However, in the case of optimization of certain structures, it is not co straightforward. An example of such constructions are bubble deck ceilings, where in order to reduce the dead weight, air cavities are used, which are regularly arranged over the entire surface of the ceiling. In the case of these slabs, the flexural stiffness is not constant in all its cross-sections, which means that the use of structural finite elements (plate or shell) for static calculations is not possible, and therefore the optimization process becomes more difficult. The paper presents a minimization procedure of the weight of bubble deck slabs using numerical homogenization and sequential quadratic programming with constraints. Homogenization allows to determine the effective stiffnesses of the floor, which in the next step are sequentially corrected by changing the geometrical parameters of the floor and voids in order to achieve the assumed deflection. The presented procedure allows to minimize the use of material in a quick and effective way by automatically determining the optimal parameters describing the geometry of the bubble deck floor cross-section.