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Simulation of thin aluminium-foil in the packaging industry
Blekinge Institute of Technology, Faculty of Engineering, Department of Mechanical Engineering.
Lunds Universitet, SWE.
Altair Engineering AB, SWE.
Saab AB, SWE.
Show others and affiliations
2017 (English)In: AIP Conference Proceedings / [ed] Brabazon D.,Ul Ahad I.,Naher S., American Institute of Physics Inc. , 2017, Vol. 1896, article id 160014Conference paper, Published paper (Refereed)
Abstract [en]

This work present an approach of how to account for the anisotropic mechanical material behaviour in the simulation models of the thin aluminium foil layer (≈10 μm) used in the Packaging Industry. Furthermore, the experimental results from uniaxial tensile tests are parameterised into an analytical expression and the slope of the hardening subsequently extended way beyond the experimental data points. This in order to accommodate the locally high stresses present in the experiments at the neck formation. An analytical expression, denominated Ramberg-Osgood, is used to describe the non-linear mechanical behaviour. Moreover it is possible with a direct method to translate the experimental uniaxial tensile test results into useful numerical material model parameters in Abaqus™. In addition to this the extended material behaviour including the plastic flow i.e. hardening, valid after onset of localisation, the described procedure can also capture the microscopic events, i.e. geometrical thinning, ongoing in the deformation of the aluminium foil. This method has earlier successfully been applied by Petri Mäkelä for paperboard material [1]. The engineering sound and parameterised description of the mechanical material behaviour facilitates an efficient categorisation of different aluminium foil alloys and aid the identification of the correct anisotropic (RD/TD/45°) mechanical material behaviour derived from the physical testing. © 2017 Author(s).

Place, publisher, year, edition, pages
American Institute of Physics Inc. , 2017. Vol. 1896, article id 160014
National Category
Other Mechanical Engineering Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:bth-15679DOI: 10.1063/1.5008189ISI: 000419825000232Scopus ID: 2-s2.0-85037691878ISBN: 9780735415805 (print)OAI: oai:DiVA.org:bth-15679DiVA, id: diva2:1168574
Conference
20th International ESAFORM Conference on Material Forming, ESAFORM,Dublin
Available from: 2017-12-21 Created: 2017-12-21 Last updated: 2019-03-28Bibliographically approved
In thesis
1. Mechanics and Failure in Thin Material Layers: Towards Realistic Package Opening Simulations
Open this publication in new window or tab >>Mechanics and Failure in Thin Material Layers: Towards Realistic Package Opening Simulations
2019 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The final goal of this PhD-work is an efficient and user-friendly finite element modelling strategy targeting an industrial available package opening application.  In order to reach this goal, different experimental mechanical and fracture mechanical tests were continuously refined to characterize the studied materials. Furthermore, the governing deformation mechanisms and mechanical properties involved in the opening sequence were quantified with full field experimental techniques to extract the intrinsic material response. An identification process to calibrate the material model parameters with inverse modelling analysis is proposed. Constitutive models, based on the experimental results for the two continuum materials, aluminium and polymer materials, and how to address the progressive damage modelling have been concerned in this work. The results and methods considered are general and can be applied in other industries where polymer and metal material are present.                                                                   

This work has shown that it is possible to select constitutive material models in conjunction with continuum material damage models, adequately predicting the mechanical behaviour in thin laminated packaging materials. Finally, with a slight modification of already available techniques and functionalities in a commercial general-purpose finite element software, it was possible to build a simulation model replicating the physical behaviour of an opening device. A comparison of the results between the experimental opening and the virtual opening model showed a good correlation.

The advantage with the developed modelling approach is that it is possible to modify the material composition of the laminate. Individual material layers can be altered, and the mechanical properties, thickness or geometrical shape can be changed. Furthermore, the model is flexible and a new opening design with a different geometry and load case can easily be implemented and changed in the simulation model. Therefore, this type of simulation model is prepared to simulate sustainable materials in packages and will be a useful tool for decision support early in the concept selection in technology and development projects.

Place, publisher, year, edition, pages
Karlskrona: Blekinge Tekniska Högskola, 2019. p. 140
Series
Blekinge Institute of Technology Doctoral Dissertation Series, ISSN 1653-2090 ; 9
Keywords
aluminium foil, FEM, LDPE, localisation, necking, polymer, progressive damage, semi-crystalline, simulation, virtual twin
National Category
Mechanical Engineering
Identifiers
urn:nbn:se:bth-17748 (URN)978-91-7295-374-1 (ISBN)
Public defence
2019-05-29, J1650, BTH, Campus Gräsvik, Karlskrona, 13:30 (English)
Opponent
Supervisors
Available from: 2019-03-28 Created: 2019-03-28 Last updated: 2019-05-09Bibliographically approved

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