Hindawi Publishing Corporation

Advances in Materials Science and Engineering

Volume 2014, Article ID 654012, 8 pages
http://dx.doi.org/10.1155/2014/654012

Research Article
Nonlinear Finite Element Analysis of the Fluted Corrugated
Sheet in the Corrugated Cardboard

Zhiguo Zhang,1,2,3 Tao Qiu,2 Riheng Song,2 and Yaoyu Sun2

1
Department of Polymer Science and Engineering, Zhejiang University, Hangzhou, Zhejiang 310027, China
2
School of Light Industry, Zhejiang University of Science and Technology, Hangzhou, Zhejiang 310023, China
3
Shengda Group Co., Ltd, Hangzhou, Zhejiang 311264, China

Correspondence should be addressed to Zhiguo Zhang; [email protected]

Received 3 February 2014; Revised 20 May 2014; Accepted 21 May 2014; Published 23 July 2014

Academic Editor: Jun Zhang

Copyright © 2014 Zhiguo Zhang et al. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

The choice of corrugated medium, flute size, combining adhesive, and linerboards can be varied to design a corrugated board with
specific properties. In this paper, the nonlinear finite element analysis of the fluted corrugated sheet in the corrugated cardboard
based on software SolidWorks2008 was investigated. The model of corrugated board with three or more flutes is reliable for stress
and displacement measurement to eliminate the influence of the number of flutes in models. According to the static pressure
test, with the increase of flute height 𝐻 or arc radius of flute, the maximum stress in the models decreased and the maximum
displacement increased. However the maximum stress and maximum displacement in the models increase nonlinearly in the static
pressure test with the increase of the flute angle 𝜃. According to the drop test, with the increase of flute height 𝐻, the maximum
stress of goods on the upper board in the drop test decreased. The maximum stress of the model in the drop test decreases firstly and
then increases with the increase of flute angle, and the optimal flute angle 𝜃 could be 60∘ for corrugated board. All the conclusions
are consistent with experimental data or product standards.

1. Introduction Common flute sizes are “A,” “B,” “C,” “E,” and “F.” The letter
designation relates to the order that the flutes were invent-
Corrugated containers are the most important structural ed, not the relative sizes. Flute size refers to the number of
application of paperboard. Corrugated cardboard is a paper- flutes per linear foot, although the actual flute dimensions
based material consisting of a fluted corrugated sheet and one for different corrugator manufacturers may vary slightly.
or two flat linerboards. It is widely used in the manufacture Measuring the number of flutes per linear foot is a more
of corrugated cardboard boxes and shipping containers. The reliable method of identifying flute size than measuring board
corrugated medium is often 0.026 pounds per square foot
thickness, which can vary due to manufacturing conditions.
(0.13 kg/m2 ) basis weight in the USA; in the UK, a 90 grams The most common flute size in corrugated cardboard boxes is
per square metre (0.018 lb/sq ft) fluting paper is common.
“C” flute. The choice of corrugated medium, flute size, com-
At the single-facer, it is heated, moistened, and formed into
bining adhesive, and linerboards can be varied to engineer
a fluted pattern on geared wheels. This is joined to a flat
a corrugated board with specific properties to match a wide
linerboard with a starch based adhesive to form single face
board. At the double-backer, a second flat linerboard is variety of potential uses.
adhered to the other side of the fluted medium to form single The structural performance of a corrugated container is
wall corrugated board. Linerboards are test liners (recycled a function of numerous factors including the quality of the
paper) or kraft paperboard (of various grades). The liner input cellulose fibers, the mechanical properties of the liner
may be bleached white, mottled white, colored, or preprinted and medium, and the structural properties of the combined
[1–3]. The basic geometry of typical twin corrugated wall board. The complicated nonlinear behavior or paper makes
board is illustrated in Figure 1. modeling of the mechanical response of corrugated board
2 Advances in Materials Science and Engineering

Table 1: Parameters of linear elastic material [18].

Numerical
Twin wall Name Unit
value
corrugated board
𝐸𝑥 7600 MPa
Elastic modulus 𝐸𝑦 4020 MPa
𝐸𝑧 38 MPa
𝐺𝑥𝑦 2140 MPa
Shear modulus 𝐺𝑥𝑧 20 MPa
Figure 1: Twin corrugated wall board structure.
𝐺𝑦𝑧 70 MPa
𝑉𝑥𝑦 0.34 —
Poisson’s ratio 𝑉𝑥𝑧 0.01 —
𝑉𝑦𝑧 0.01 —
and structures composed of corrugated board a difficult task
Density 404.5 kg/m3
[4].
Numerous studies have been focused on the properties
of corrugated cardboard and external environment’s effects Table 2: Parameters of rigid plate material.
on the performance of corrugated carton [5–10]. Gilchrist
Name Numerical value Unit
et al. [4] have developed nonlinear finite element mod-
Elastic modulus 1.0 × 1012 N/m2
els for corrugated board configurations. Results from the
finite element simulations correlated reasonably well with Density 1.0 × 10−8 kg/m3
the analogous experimental measurements performed using Poisson’s ratio 0.3 —
actual corrugated board specimens. Biancolini and Brutti
[11] have developed a finite element “corrugated board” by
means of a dedicated homogenization procedure in order analysis of flute size. Yuan et al. [16, 17] have developed
to investigate the buckling of a complete package. The FEM a model of UV-shaped corrugated cardboard by ANSYS.
model of the package, assembled with this new element, can The results show that the closer the model to the U-shaped
accurately predict the experimental data of incipient buckling flute, the larger the corrugated board strain becomes. It is
observed during the standard box compression test, despite consistent with the empirical data, which prove the feasibility
the few degrees of freedom and the minimal computational of finite element analysis method. In this paper, we focus on
effort. Biancolini [12] also presented a numerical approach the investigation of nonlinear finite element analysis of the
to evaluating the stiffness parameters for corrugated board. fluted corrugated sheet in the corrugated cardboard based on
The method is based on a detailed micromechanical rep- software SolidWorks2008. The shape and size of flute will be
resentation of a region of corrugated board modelled by discussed with the help of SolidWorks and compared with the
means of finite elements. Conde et al. [13] have developed empirical data.
a methodology for modelling corrugated board adhesive
joints subjected to shear, considered to be the main load in 2. Modeling
most of these joints. The corrugated board adhesive joint
model reproduced quite well the stiffness obtained in the test SolidWorks2008 has powerful structural modeling functions,
samples, as well as the failure load with a deviation of less than among which Cosmos/Works is a function module which is
14%. specially used to make finite element analysis on structure.
Biancolini et al. [1] compared results obtained from the The model of common UV-shaped corrugated board is
simplified formula, an extended formula, and two numerical shown in Figure 2. In Figure 2, 𝐿 is flute length, 𝐻 is flute
models developed by authors using finite elements (FE): an height, ℎ is facing paper thickness, 𝛿 is fluting paper thickness,
FE model realised with homogenised elements and an FE 𝜃 is flute angle, and 𝑟 is arc radius.
model representing the entire corrugation geometry. Numer- The principal aim of this work is to study the fluted corru-
ical results of the capability to resist stacking loads obtained gated sheet. So we added a piece of rigid plate with large
with FE models were consistent with experimental results. elastic modulus on upper facing paper (as shown in Figure 3)
Haj-Ali et al. [14] presented a refined nonlinear finite ele- to eliminate the influence of the facing paper deformation.
ment modeling approach for analyzing corrugated cardboard The maximum stress and strain of the improved model occur
material and structural systems. This method can accurately in the point in which flute contact with the upper facing paper
predict overall mechanical behavior and ultimate failure for in all cases. The material parameters of corrugated board
wide range corrugated systems. Talbi et al. [15] presented an model are given in Table 1 [18]. The material parameters of
analytical homogenization model for corrugated cardboard rigid plate model are given in Table 2 from the SolidWorks
and its numerical implementation in a shell element. material library.
The shape and size of flute have an important effect on
the performance of corrugated cardboard. However, there are 3. Results and Discussion
no strict standards of flute size parameter to achieve the best
elasticity and compressive strength of corrugated cardboard. 3.1. The Numbers of Flutes in Models. In order to eliminate
There is also little literature regarding the finite element the influence of the number of flutes in models, a series
Advances in Materials Science and Engineering 3

r R0.25
R0.55
h

0.50
𝛿
H
0.30
𝜃

R0.25
+ + +
60∘ 60∘
h

0.50
2L

Figure 2: Model of UV-shaped corrugated board.

0.40
Figure 4: Model of corrugated board with two flutes.

From Figure 8, we can see that, with the flute height

𝐻 increased, the maximum stress in the models decreased
and the maximum displacement increased. Therefore, with
the flute height 𝐻 increased, the flat compression strength
of corrugated board decreased and cushioning properties of
corrugated board increased. As is well known, the cushioning
Figure 3: Improved model of UV-shaped corrugated board with properties of different shapes of corrugated cardboard have
rigid plate. the sequence A > C > B > E, and the flat compression strength
of corrugated board has the sequence A < C < B < E. Our
simulation results are consistent with these conclusions.

of models with different number of flutes were built and

shown in Figure 4. The numbers of flutes in models are 2, 3.3. Arc Radius 𝑟. Effects of arc radius 𝑟 on the mechanical
3, 4, and 5. Fixing the bottom of models and then a static properties of corrugated cardboard model were investigated
pressure test were made with a pressure of 150 Pa on the top in this section. A series of models with different arc radius
floor. Then the stress and displacement contours of models of of flute were built and shown in Figure 9. The arc radius 𝑟
corrugated board were obtained as shown in Figure 5 (model in models are 0, 0.1, 0.2, 0.25, 0.3, 0.35, and 0.4 mm. Fixing
with three flutes as example). From above calculation, the the bottom of models and then a static pressure test were
maximum displacement and maximum stress of the models made with a pressure of 150 Pa on the top floor. Then the
with different number of flutes were obtained and the results maximum displacement and maximum stress of the models
are shown in Figure 6. with different arc radius were obtained and the results are
From Figure 6, we can see that, with the number of flutes shown in Figure 10.
increased, the maximum stress in the models increased and From Figure 10, we can see that, with the arc radius of flute
the maximum displacement decreased. While the number increased, the maximum stress in the models decreased and
of flutes increased to 3 or more, the maximum stress and the maximum displacement increased. It means that when
displacement changed slightly. Therefore, the model of cor- the arc radius 𝑟 increases the flat compression properties get
rugated board with three or more flutes is reliable for stress worse and the cushioning properties get better. In fact, the
and displacement measurement. In the coming simulation, smaller the arc radius, the closer the model to the V-shaped
the numbers of flutes in the models are all greater than 2. flute; the larger the arc radius, the closer the model to U-
shaped flute. The simulation result also verified that the flat
compression properties of V-shaped flute corrugated board
3.2. Flute Height 𝐻. Effects of flute height 𝐻 on the mechan- are better than that of the U-shaped flute corrugated board
ical properties of corrugated cardboard model were investi- and its cushioning properties are worse than that of the U-
gated. A series of models with different flute height 𝐻 were shaped flute.
built and shown in Figure 7. The flute heights 𝐻 in models Actually, the triangle is the most stable structure. It is
are 2, 3, 4, and 5 mm. These models can be roughly classified difficult to deform when a force was applied at the vertex of a
as A flute (5 mm), C flute (4 mm), B flute (3 mm), and E flute triangle. But this structure is not suitable for the cushioning
(2 mm). Fixing the bottom of models and then a static pres- design. As the arc radius 𝑟 increases, the maximum displace-
sure test were made with a pressure of 150 Pa on the top floor. ments of the structure increase. So the stress can be dispersed
Then the maximum displacement and maximum stress of the to other parts rather than concentrating on one point. In
models with different flute height 𝐻 were obtained and the this situation the cushioning properties of corrugated board
results are shown in Figure 8. get better to protect goods. In order to meet the needs of
4 Advances in Materials Science and Engineering

7.300e + 003
6.692e + 003
6.084e + 003
5.475e + 003

Von Mises (N/m2 )

4.867e + 003
4.259e + 003
3.650e + 003
3.042e + 003
2.434e + 003
1.825e + 003
1.217e + 002
6.087e + 002
3.235e − 001
(a) Stress contours
1.270e − 012
1.164e − 012
1.058e − 012
9.522e − 013
8.464e − 013

URES (m)
7.406e − 013
6.348e − 013
5.290e − 013
4.232e − 013
3.174e − 013
2.116e − 013
1.058e − 013
1.000e − 033
(b) Displacement contours

Figure 5: The stress and displacement contours of models of corrugated board with three flutes.

900 10
Maximum displacement (×10−12 m)

Maximum displacement (×10−12 m)

1.5 9
2500 8
800
Maximum stress (Pa)

1.4 7
Maximum stress (Pa)

2000 6
700 1.3 5
1500 4
1.2 3
600
1000 2
1.1 1
500 500 0
1 2 3 4 5 6 1 2 3 4 5 6
e number of flutes Flute height (mm)

Figure 6: Maximum stresses and maximum displacements of Figure 8: Maximum stresses and maximum displacements of
corrugated board models with different number of flutes. corrugated board models with different flute height.
0
.4
R0
0.40
0.50

R0.35

5 0.30
0.50
0.40

R0
.40
0.40
0.50

3 0.30
Figure 7: Model of corrugated board with flute height 𝐻 of 5 mm.
0.40
0.50

9.69
packaging cushioning design, we should determine the arc
radius 𝑟 according to the actual packaging requirements. Figure 9: Model of corrugated board with arc radius of 0.35 mm.
Advances in Materials Science and Engineering 5

1000 2.5 2500

Maximum displacement (×10−12 m)

14

Maximum displacement (×10−12 m)

900 2000 12
Maximum stress (Pa)

Maximum stress (Pa)

2.0
10
800 1500
8
700 1.5 1000 6

4
600 500
1.0 2
500 0 0
−0.1 0.0 0.1 0.2 0.3 0.4 0.5 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Arc radius (mm) Flute angle (∘ )

Figure 10: Maximum stresses and maximum displacements of Figure 12: Maximum stresses and maximum displacements of
corrugated board models with different arc radius of flute. corrugated board models with different flute angle 𝜃.

𝜙1.10 R0.25
A
0.40
0.50

3 0.30
20∘
0.50
0.40

Figure 13: The drop test model with different flute height.
R0.25

Figure 11: Model of corrugated board with flute angle of 40∘ .

3.5. Drop Test
3.5.1. Flute Height 𝐻. Both primary (consumer) packages
and shipping containers have a risk of being dropped or
3.4. Flute Angle 𝜃. Effects of flute angle 𝜃 on the mechanical being impacted by other items. Package integrity and product
properties of corrugated cardboard model were investigated protection are important packaging functions. Drop tests are
in this section. A series of models with different flute angle conducted to measure the resistance of packages and prod-
𝜃 were built and shown in Figure 11. The flute angles 𝜃 in ucts to controlled laboratory shock and impact. Drop testing
models are 40, 50, 60, 70, 80, 90, 100, 110, and 120∘ . Fixing the also determines the effectiveness of package cushioning to
bottom of models and then a static pressure test were made isolate fragile products from shock.
with a pressure of 150 Pa on the top floor. Then the maxi- Effects of flute height 𝐻 on the dynamic mechanical
mum displacement and maximum stress of the models with properties of corrugated cardboard model in the drop test
different flute angle 𝜃 were obtained and the results are shown based on Cosmos/Works were investigated. A series of
in Figure 12. models with different flute height 𝐻 were built and shown in
From Figure 12, we can see that, with the increase of the Figure 7. The flute heights 𝐻 in models are 2, 3, 4, and 5 mm.
flute angle 𝜃, the maximum stress and maximum displace- The drop test model was shown in Figure 13. A simplified
ment in the models increase nonlinearly. The maximum stress model of corrugated board and goods on the upper board
and maximum displacement change slowly when 𝜃 is less were investigated. Drop height is 0.3 m, initial velocity is
than 60∘ and then increase sharply when 𝜃 is larger than 60∘ . 0 m/s, acceleration of gravity is 9.81 m/s2 , and impact time is
In addition, the number of flute per unit length increases as 600 𝜇s. The material of the object on the upper board is Acry-
the 𝜃 decreases, and it means that the corrugated board needs lonitrile Butadiene Styrene (ABS) and the mass is 1.224 ×
more materials. Therefore, the optimal flute angle 𝜃 could be 10−4 kg. Then the stress and displacement contours of models
60∘ for corrugated board. According to the Chinese national of corrugated board were obtained and shown in Figure 14
standards “Corrugated board and standard test method” (model with flute height 𝐻 of 5 mm). In order to investigate
(GB6544∼6548-86), the UV-shaped flute corrugated board the stress of goods on the upper board in the drop test, we
should be 60∘ in the manufacture process. The simulation selected 2 points (A and B point as shown in Figure 13) from
result is consistent with the standards of corrugated board. the model as the object of study. Then the time-dependent
6 Advances in Materials Science and Engineering

4.682e + 005
4.294e + 005
3.905e + 005
3.517e + 005

Von Mises (N/m 2 )

3.129e + 005
2.741e + 005
2.353e + 005
1.965e + 005
1.577e + 005
1.188e + 005
8.003e + 004
4.122e + 004
2.405e + 003
(a) Stress contours
1.605e − 003
1.474e − 003
1.343e − 003
1.211e − 003
1.080e − 003
9.489e − 004

URES (m)
8.176e − 004
6.864e − 004
5.551e − 004
4.239e − 004
2.926e − 004
1.614e − 004
3.015e − 005
(b) Displacement contours

Figure 14: The stress and displacement contours of model with flute height 𝐻 of 5 mm in drop test.

2.0
1.20
1.8
1.00
Maximum stress (×105 Pa)

1.6
Von Mises (×105 Pa)

8.00 1.4

1.2
6.00
1.0

4.00 0.8

0.6
2.00
2 3 4 5
0.00 Flute height (mm)
0.97 100.77 200.58 300.38 400.18 499.79 599.79
A
Time (𝜇s) B
A Figure 16: Maximum stress of A, B point in the models with
B different flute height 𝐻 in the drop test.
Figure 15: Time-dependent stress of A, B point in drop test (model
with flute height 𝐻 of 5 mm).

From Figure 16, we can see that, with the increase of flute
stress of A, B point in the drop test was obtained and shown height 𝐻, the maximum stress of goods on the upper board
in Figure 15 (model with flute height 𝐻 of 5 mm). From above in the drop test decreased. Therefore, with the increase of
simulation, the maximum stresses of A, B point in the models flute height 𝐻, the cushioning properties of corrugated board
with different flute height 𝐻 in the drop test were obtained increased. This conclusion is consistent with the conclusions
and the results are shown in Figure 16. of Section 3.2.
Advances in Materials Science and Engineering 7

3.0
Drop direction

2.5

Maximum stress (×105 Pa)

2.0

1.5

1.0

B A
0.5
30 40 50 60 70 80 90 100 110 120
Figure 17: The drop test model with different flute angle 𝜃. Flute angle (∘ )

A
B

2.50 Figure 19: Maximum stress of A, B point in the models with

different flute angle in the drop test.
2.00
Von Mises (×105 Pa)

point in the models with different flute angle 𝜃 in the drop test
1.50 were obtained and the results are shown in Figure 19.
From Figure 19, we can see, that with the increase of flute
1.00
angle, the maximum stress of the model in the drop test
decreases firstly and then increases. The maximum stress of
the corrugated board bears is smallest when the flute angle
5.00 𝜃 reaches 60∘ . The reason is that the stress of the corrugated
board could be dispersed to the flute structure efficiently and
then reduces the maximum stress of the corrugated board in
0.00 drop test. Therefore, the optimal flute angle 𝜃 could be 60∘
1.18 124.94 240.70 360.46 480.22 599.98 for corrugated board. This conclusion is consistent with the
Time (𝜇s) conclusions of Section 3.4.
A
B
4. Conclusions
Figure 18: Time-dependent stress of A, B point in drop test (model
with flute angle 𝜃 of 40∘ ). The shape and size of flute have an important effect on the
performance of corrugated cardboard. In this paper, the non-
linear finite element analysis of the fluted corrugated sheet in
the corrugated cardboard based on software SolidWorks2008
was investigated. The obtained conclusions are as follow.
3.5.2. Flute Angle 𝜃. Effects of flute angle 𝜃 on the dynamic
mechanical properties of corrugated cardboard model in the
(1) According to the static pressure test, with the flute
drop test based on Cosmos/Works were investigated. A series
height 𝐻 increased, the maximum stress in the
of models with different flute angle 𝜃 were built and shown
models decreased and the maximum displacement
in Figure 11. The flute angles 𝜃 in models are 40, 50, 60, 80,
increased.
and 100∘ . The drop test model was shown in Figure 17. Drop
height is 0.3 m, initial velocity is 0 m/s, acceleration of gravity (2) According to the static pressure test, with the arc
is 9.81 m/s2 , and impact time is 600 𝜇s. The stress distribution radius of flute increased, the maximum stress in the
of corrugated cardboard was obtained and we have found models decreased and the maximum displacement
that the maximum stress occurs in the point which fluted increased.
corrugated sheet contact with the ground in all cases. So
we selected 2 points (A and B point as shown in Figure 17) (3) According to the static pressure test, with the increase
from the model as the object of study in the drop test. Then of the flute angle 𝜃, the maximum stress and max-
the time-dependent stress of A, B point in the drop test was imum displacement in the models increase nonlin-
obtained and shown in Figure 18 (model with flute angle 𝜃 of early. The optimal flute angle 𝜃 could be 60∘ for corru-
40∘ ). From above simulation, the maximum stresses of A, B gated board.
8 Advances in Materials Science and Engineering

(4) According to the drop test, with the increase of flute of corrugated board boxes: an experimental analysis by using
height 𝐻, the maximum stress of goods on the upper digital image stereocorrelation,” Composite Structures, vol. 93,
board in the drop test decreased. no. 11, pp. 2861–2873, 2011.
(5) According to the drop test, with the increase of flute [11] M. E. Biancolini and C. Brutti, “Numerical and experimental
investigation of the strength of corrugated board packages,”
angle, the maximum stress of the model decreases
Packaging Technology and Science, vol. 16, no. 2, pp. 47–60, 2003.
firstly and then increases. The maximum stress of
[12] M. E. Biancolini, “Evaluation of equivalent stiffness properties
the corrugated board bears is smallest when the flute
of corrugated board,” Composite Structures, vol. 69, no. 3, pp.
angle 𝜃 reaches 60∘ . Therefore, the optimal flute angle 322–328, 2005.
𝜃 could be 60∘ for corrugated board.
[13] I. Conde, B. Garcı́a, E. Liarte, and M. A. Jiménez, “Analysis
All the conclusions are consistent with experimental data of adhesive joints in corrugated board under shear loading,”
or product standards. International Journal of Adhesion and Adhesives, vol. 38, pp. 50–
57, 2012.
[14] R. Haj-Ali, J. Choi, B.-S. Wei, R. Popil, and M. Schaepe, “Refined
Conflict of Interests nonlinear finite element models for corrugated fiberboards,”
Composite Structures, vol. 87, no. 4, pp. 321–333, 2009.
The authors declare that there is no conflict of interests
regarding the publication of this paper. [15] N. Talbi, A. Batti, R. Ayad, and Y. Q. Guo, “An analytical homog-
enization model for finite element modelling of corrugated
cardboard,” Composite Structures, vol. 88, no. 2, pp. 280–289,
Acknowledgments 2009.
[16] W. Yuan, M. G. Zhang, Z. D. Liao et al., “Corrugated board
This work was financially supported by the National Natural flute-shaped finite element analysis and optimization,” Applied
Science Foundation of China (51206148, 51106140), Major Mechanics and Materials, vol. 477-478, pp. 1205–1209, 2014.
Programs of Sci & Tech, Department of Science and Tech- [17] W. Yuan, J. X. Sun, G. M. Zhang et al., “Corrugated board UV
nology of Zhejiang Province (2008C12062, 2013C03017-4), flute-shaped structure size optimization design based on the
and Zhejiang Provincial Natural Science Foundation of China finite element,” Applied Mechanics and Materials, vol. 469, pp.
(Y1110642, Y407311). The authors are thankful for the finan- 213–216, 2014.
cial support of Zhejiang Provincial Key Disciplines “Pulp and [18] H. Guang-jun, H. Xiang, and F. Wei, “Finite element modeling
Paper Engineering.” and buckling analysis of corrugated box,” Packaging Engineer-
ing, vol. 30, no. 3, pp. 34–35, 2009.
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