Application of fluidic media based processes to deep-drawing of paper and paperboard
The production of multi-dimensionial packaging solutions and construction parts with curved geometry of paper and paperboard is until now not satisfactory possible. For the production of curved paperboard parts fiber-moulding and deep drawing processes are possible. Latter option has advantages in relation to energy efficiency, stability and surface condition of the finished product, but very little research has been done so far. Industrial deep drawn parts from paperboard have currently mostly simple geometries. The development of new products is based on practical experience of the manufacturer and on cost and time intensive experiments. Especially, with respect to new more complex parts there are strict limits.
The aim of the research project is to extend the spread of application of deep drawing processes for paperboard. To do this, basics of the raw material, the processes and the development have to be developed. The currently used experimental and cost intensive procedure of product development shall be improved by focused investigation of material characterization, process design and numerical simulation. The research project shall adapt fluid media based forming technologies to paperboard forming. These technologies are well known in metal forming and shall lead to fundamentals for applying the processes in paperboard industry. In focus are experimental investigations of the fluid based forming of paperboard and the establishment of formable paperboard. Additionally the numerical modelling of the material behavior during the forming process is aspired.
To fulfill the objectives of the research project the forming process will be observed having regard to the raw material and the material behavior within the cooperation of PMV (Fachgebiet Papierfabrikation und Mechanische Verfahrenstechnik – TU Darmstadt) and PtU. To optimize the material towards formability the effects of varying parameters like fiber curl, chemical mixture, manufacturing based pre-straining and the anisotropy will be determined. Additionally a detailed material characterization is scheduled to compare referenced laboratory specimen with industrial paperboard. This serves to get first experimental data for the material model and the development of the specimens’ geometry. The fluid based forming process will be developed further and adapted. Based on the generated data a material model especially for designing and developing formed paperboard products will be developed and used for example geometry design.
The aim of the project was to extend the application range of deep drawing processes for paper. This should be done through establishing raw material, process and design basics. With the help of the made investigations, significant information have been gained. With the fluid based forming technology it is now possible to form three-dimensional parts from paperboard. Further, it has been carried out that the forming limits of paperboard can be extended through a hydrostatic counter pressure. The product design algorithm which was developed within this project leads to a faster and more cost efficient process of product design. The algorithm includes focused material characterization, process design and numerical simulation. Simplified material models help to check the feasibility of formed paperboard products and can give statements about the geometry and its optimization. For the process modelling only a tensile stiffness orientation test (TSO) and a tensile tests at four different moisture contents are necessary. Additionally, the friction has to be determined which needs the knowledge of the boundaries of moisture content, temperature, surface pressure and process speed of the process. For fast statements about forming limits and the feasibility of new geometries an orientation based forming limit diagram (OBFLD) has been developed.
For further information and to get the final report of the research project please contact the VDP (German Pulp and Paper Association) or one of the research departments.
The IGF-Research Project 17788 N, supported by the German Pulp and Paper Association, was funded in the scope of the “Progamm zur Förderung der Industiellen Gemeinschaftsforschung” (IGF) via the German Federation of Industrial Research Associations (AiF) by the German Ministry for Economy and Energy as decided by the German parliament.
Furthermore, we thank all involved companies for the support of the research project “Application of fluidic media based processes to deep-drawing of paper and paperboard”:
- AB Enzymes
- A. Obenauf GmbH & Co. KG
- BASF SE
- BYK-Chemie GmbH
- DST Dräxlmaier Systemtechnik
- Epurex Films GmbH & Co. KG
- Gebrüder Dorfner GmbH & Co. KG
- Feinpappenwerk Gebr. Schuster GmbH & Co. KG
- Hosti International GmbH
- Innowep GmbH
- Schäfer OHG
- Schoeller Technocell GmbH & Co. KG
- Stora Enso FPB Holding GmbH & Co. KG
- Moritz J. Weig GmbH & Co. KG