The article presents a simplified method for determining the strength of a corrugated board packaging subjected to dynamic transport loads. The proposed algorithm consists of several calculation steps: (1) a static analysis of the compressive strength of the package, (2) an analysis of random vibrations in the frequency domain, used to determine the resonance frequencies, and (3) a dynamic analysis of the package loaded with computed resonant frequencies. For this purpose, numerical models of the static compression test of the packaging before and after the dynamic analysis of the package subjected to general transport loads were developed. In order to validate the model, the laboratory packaging compression tests were also performed for samples of boxes with 3-layer cardboard. Thanks to this, it was possible to verify the results of numerical simulations of compression tests for several box geometries. Which, in turn, allowed for the development of a method based on dynamic and post-dynamic (static) numerical analysis, allowing to determine with high accuracy the resistance of selected packaging to vibrations and dynamic loads. The results of the (validated experimentally) numerical analysis prove the usefulness of the simplified method presented here for precise estimation of the load capacity of various packages dynamically loaded during transport.

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.

The paper presents a modified finite element method for nonlinear analysis of 2D beam structures. To take into account the influence of the shear flexibility, a Timoshenko beam element was adopted. The algorithm proposed enables using complex material laws without the need of implementing advanced constitutive models in finite element routines. The method is easy to implement in commonly available CAE software for linear analysis of beam structures. It allows to extend the functionality of these programs with material nonlinearities. By using the structure deformations, computed from the nodal displacements, and the presented here generalized nonlinear constitutive law, it is possible to iteratively reduce the bending, tensile and shear stiffnesses of the structures. By applying a beam model with a multi layered cross-section and generalized stresses and strains to obtain a representative constitutive law, it is easy to model not only the complex multi-material cross-sections, but also the advanced nonlinear constitutive laws (e.g. material softening in tension). The proposed method was implemented in the MATLAB environment, its performance was shown on the several numerical examples. The cross-sections such us a steel I-beam and a steel I-beam with a concrete encasement for different slenderness ratios were considered here. To verify the accuracy of the computations, all results are compared with the ones received from a commercial CAE software. The comparison reveals a good correlation between the reference model and the method proposed.

The article presents a modified finite element (FE) based algorithm for nonlinear analysis of 2D beam structures, which takes into account the influence of the shear forces. The method proposed enables using complex materials with nonlinearities without the need of implementing advanced constitutive models in FE routines. It can be directly integrated with commonly available FE software for linear analysis of beam structures, so its functionality can be easily extended also with material nonlinearities. The presented approach adopts the generalized constitutive law algorithm to iteratively modify the stiffness of beam element. To address an influence of a shear stiffness, a Timoshenko beam element was used. The methodology was implemented and its performance was verified on several numerical examples. For validation, the displacements and the ultimate loads were compared with the values from a commercial FE software. The results shown a good correlation between the reference model and the method proposed.

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.

Corrugated cardboard is an ecological material, mainly because, in addition to virgin cellulose fibers also the fibers recovered during recycling process are used in its production. However, the use of recycled fibers causes slight deterioration of the mechanical properties of the corrugated board. In addition, converting processes such as printing, die-cutting, lamination, etc. cause micro-damage in the corrugated cardboard layers. In this work, the focus is precisely on the crushing of corrugated cardboard. A series of laboratory experiments were conducted, in which the different types of single-walled corrugated cardboards were pressed in a fully controlled manner to check the impact of the crush on the basic material parameters. The amount of crushing (with a precision of 10 micrometers) was controlled by a precise FEMat device, for crushing the corrugated board in the range from 10 to 70 % of its original thickness. In this study, the influence of crushing on bending, twisting and shear stiffness as well as a residual thickness and edge crush resistance of corrugated board was investigated. Then, a procedure based on a numerical homogenization, taking into account a partial delamination in the corrugated layers to determine the degraded material stiffness was proposed. Finally, using the empirical-numerical method, a simplified calculation model of corrugated cardboard was derived, which satisfactorily reflects the experimental results.

Artificial intelligence is increasingly used in various branches of engineering. In this article, artificial neural networks are used to predict the crush resistance of corrugated packaging. Among the analysed packages were boxes with ventilation openings, packages with perforations, and typical flap boxes, which makes the proposed estimation method very universal. Typical shallow feedforward networks were used, which are perfect for regression problems, mainly when the set of input and output parameters is small, so no complicated architecture or advanced learning techniques are required. The input parameters of the neural networks are selected so as to take into account not only the material used for the production of the packaging, but also the dimensions of the box and the impact of ventilation holes and perforations on the load capacity of individual walls of the packaging. In order to maximize the effectiveness of neural network training process, the group of input parameters was changed so as to eliminate those to which the sensitivity of the model was the lowest. This allowed the selection of the optimal configuration of training pairs for which the estimation error was on the acceptable level. Finally, models of neural networks were selected, for which the training and testing error did not exceed 10%. The demonstrated effectiveness allows to conclude that the proposed set of universal input parameters is suitable for efficient training of a single neural network model capable of predicting the compressive strength of various types of corrugated packaging.

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.

Paper is a material whose mechanical properties are highly dependent on humidity and temperature. Which naturally also builds the relationship between the stiffness and strength of corrugated board and changing weather conditions. In this paper, attention is focused on the dependence of the physical properties of the cardboard on changes in humidity and temperature, which undergo dynamic fluctuations both during the production of corrugated board and during its storage. Two techniques were used to test this effect, namely numerical homogenization and global sensitivity analysis. Both methods were implemented to determine the theoretical relationships between the change in humidity and/or temperature in each layer of corrugated board and its global bending, compression and shear stiffness. The procedure was used to analyze different types of 5-ply and 3-ply cardboard. The obtained results allowed to build a complete map of the relationship between the change in humidity of selected layers and the strength characteristics of the full assembly.