Charakterisierung der Prozesskraftkomponenten beim mehrdimensionalen Umformen von Karton durch Ziehen

Gegenstand dieser Arbeit ist die Entwicklung einer Methode zur Charakterisierung der komplexen Belastungssituation beim Tiefziehen mit unmittelbarer Kompression von Karton innerhalb geeigneter Ersatzversuche und deren Validierung mit Hilfe eines empirischen Models. Das Tiefziehen mit unmittelbarer Kompression stellt eine Möglichkeitzur Herstellung von dreidimensionalen Hohlkörpern mit hohem Umformgrad aus naturfaserbasierten, flächigen Halbzeugen mit geringem Vorfertigungsgrad dar.Aufbauend auf der Darstellung und Abgrenzung des Umformverfahrens werden relevante Prozessgrößen und deren Charakterisierung durch geeignete Ersatzversuche aus dem Stand der Wissenschaft recherchiert und bewertet. Zudem werden Möglichkeiten erörtert, die Ergebnisse der Ersatzversuche mit den Daten aus dem Umformverfahren zu vergleichen. Aus den technischen und wissenschaftlichen Defiziten ergibt sich die Zielsetzung und weitere Vorgehensweise dieser Arbeit.Zur Lösung der Problemstellung werden den identifizierten Prozessgrößen geeignete Ersatzversuche aus dem Stand der Technik zugeordnet bzw. neue Ersatzversuche entwickelt und im Rahmen eines modularen Versuchsstandes technisch umgesetzt. Zur Vorbereitung der experimentellen Analyse der ausgewählten Ersatzversuche werden Referenzversuche mit dem Umformverfahren innerhalb festgelegter Parametergrenzen durchgeführt. Bei der anschließenden Durchführung der Ersatzversuche wird vor allem die Verlässlichkeit der Ergebnisse berücksichtigt, indem die Anzahl der Versuche jeder Versuchsreihe an die Ergebnisauswertung angepasst wird.Durch die Modifikation des Umformverfahrens können die Ergebnisse der Ersatzversuche innerhalb eines stufenweise komplexer werdendes, empirischen Modelsmit denen des Referenzversuchs verglichen und bewertet werden. Die Charakterisierung der Prozesskraftkomponenten wird für vier faserbasierte Materialien durchgeführt,die teilweise mit einer polymeren Funktionsschicht ausgestattetsind.Abschließend werden die Ergebnisse dieser Arbeit zusammengefasst dargestellt und daraus folgende Forschungsansätze abgeleitet.The purpose of this thesis is to present a newly developed method to investigate thecomplexload situation during the deep-drawing of paperboard within suitable substitute tests and its validation withinan empirical model.Deep drawing with direct compression represents analternativefor the production of three-dimensional traysfrom natural, fiber-based materials with a low degree of prefabrication.Based on the definition and description of the deep-drawing process within the literature, relevant process forces and associated substitute tests are identifiedand discussed. In addition, approachesare discussed to compare the results of the substitute tests with the data from the deep-drawingprocess. The objective and further procedure of this thesisresults from the technical and scientific deficits.The approach of this thesisis it to present a new, modular testing rig based on the substitute test which were chosen from the literature or were newly developed.In preparation ofthe experimental analysis of the selected substitutetests, reference tests are carried out with the forming process within specified parameter limits. In the subsequent implementation of the substitutetests, the reliability of the results is consideredabove all by adapting the number of tests in each test series parallel to the evaluation of the results. By modifying the forming process, the results of the substitute tests can be compared and evaluated with those of the reference test within an empirical model that becomes progressively more complex. The characterization of the process force components iscarried out for four fiber-based materials, some of which are equipped with a polymer functional layer.Finally, the results of this work are summarized,and the following research approaches are derived from them

New Method to Evaluate the Frictional Behavior within the Forming Gap during the Deep Drawing Process of Paperboard

To evaluate the influence of different normal forces and contact temperatures on the frictional behavior of paperboard during the deep drawing process, a new measurement punch was developed to measure the normal force, which induced the friction within the gap between the forming cavity and punch. The resulting dynamic coefficient of friction was calculated and reproduced via a new developed substitute test for the friction measurement device, which was first introduced in Lenske et al. (2017). The normal force within the forming gap during the deep drawing process was influenced by the blankholder force profile, the contact temperature, and the fiber direction. The friction measurements with the substitute test showed a strong dependency between the applied normal force and the dynamic coefficient of friction. Furthermore the frictional behavior was influenced by the contact temperature and the wrinkle formation

Gastight Paperboard Package: A new Step in Food Packaging

Packages made from coated paperboard are currently used in food packaging for frosted or microwave food. These cups are usually deep drawn from flat paperboard blanks. The blanks are pre-creased to control the material overflow that appears during drawing. The resulting wrinkles in the sealing area have to be considered as capillary tubes allowing the gas exchange between the package and the environmental atmosphere. A new technological approach in 3D forming enables the prevention of capillary tubes in the sealing area. The result is a gas-tight sealable paperboard cup which is limited by its coating concerning the degree of gas tightness

Charakterisierung der Prozesskraftkomponenten beim mehrdimensionalen Umformen von Karton durch Ziehen

Gegenstand dieser Arbeit ist die Entwicklung einer Methode zur Charakterisierung der komplexen Belastungssituation beim Tiefziehen mit unmittelbarer Kompression von Karton innerhalb geeigneter Ersatzversuche und deren Validierung mit Hilfe eines empirischen Models. Das Tiefziehen mit unmittelbarer Kompression stellt eine Möglichkeitzur Herstellung von dreidimensionalen Hohlkörpern mit hohem Umformgrad aus naturfaserbasierten, flächigen Halbzeugen mit geringem Vorfertigungsgrad dar.Aufbauend auf der Darstellung und Abgrenzung des Umformverfahrens werden relevante Prozessgrößen und deren Charakterisierung durch geeignete Ersatzversuche aus dem Stand der Wissenschaft recherchiert und bewertet. Zudem werden Möglichkeiten erörtert, die Ergebnisse der Ersatzversuche mit den Daten aus dem Umformverfahren zu vergleichen. Aus den technischen und wissenschaftlichen Defiziten ergibt sich die Zielsetzung und weitere Vorgehensweise dieser Arbeit.Zur Lösung der Problemstellung werden den identifizierten Prozessgrößen geeignete Ersatzversuche aus dem Stand der Technik zugeordnet bzw. neue Ersatzversuche entwickelt und im Rahmen eines modularen Versuchsstandes technisch umgesetzt. Zur Vorbereitung der experimentellen Analyse der ausgewählten Ersatzversuche werden Referenzversuche mit dem Umformverfahren innerhalb festgelegter Parametergrenzen durchgeführt. Bei der anschließenden Durchführung der Ersatzversuche wird vor allem die Verlässlichkeit der Ergebnisse berücksichtigt, indem die Anzahl der Versuche jeder Versuchsreihe an die Ergebnisauswertung angepasst wird.Durch die Modifikation des Umformverfahrens können die Ergebnisse der Ersatzversuche innerhalb eines stufenweise komplexer werdendes, empirischen Modelsmit denen des Referenzversuchs verglichen und bewertet werden. Die Charakterisierung der Prozesskraftkomponenten wird für vier faserbasierte Materialien durchgeführt,die teilweise mit einer polymeren Funktionsschicht ausgestattetsind.Abschließend werden die Ergebnisse dieser Arbeit zusammengefasst dargestellt und daraus folgende Forschungsansätze abgeleitet.The purpose of this thesis is to present a newly developed method to investigate thecomplexload situation during the deep-drawing of paperboard within suitable substitute tests and its validation withinan empirical model.Deep drawing with direct compression represents analternativefor the production of three-dimensional traysfrom natural, fiber-based materials with a low degree of prefabrication.Based on the definition and description of the deep-drawing process within the literature, relevant process forces and associated substitute tests are identifiedand discussed. In addition, approachesare discussed to compare the results of the substitute tests with the data from the deep-drawingprocess. The objective and further procedure of this thesisresults from the technical and scientific deficits.The approach of this thesisis it to present a new, modular testing rig based on the substitute test which were chosen from the literature or were newly developed.In preparation ofthe experimental analysis of the selected substitutetests, reference tests are carried out with the forming process within specified parameter limits. In the subsequent implementation of the substitutetests, the reliability of the results is consideredabove all by adapting the number of tests in each test series parallel to the evaluation of the results. By modifying the forming process, the results of the substitute tests can be compared and evaluated with those of the reference test within an empirical model that becomes progressively more complex. The characterization of the process force components iscarried out for four fiber-based materials, some of which are equipped with a polymer functional layer.Finally, the results of this work are summarized,and the following research approaches are derived from them

Charakterisierung der Prozesskraftkomponenten beim mehrdimensionalen Umformen von Karton durch Ziehen

Gegenstand dieser Arbeit ist die Entwicklung einer Methode zur Charakterisierung der komplexen Belastungssituation beim Tiefziehen mit unmittelbarer Kompression von Karton innerhalb geeigneter Ersatzversuche und deren Validierung mit Hilfe eines empirischen Models. Das Tiefziehen mit unmittelbarer Kompression stellt eine Möglichkeitzur Herstellung von dreidimensionalen Hohlkörpern mit hohem Umformgrad aus naturfaserbasierten, flächigen Halbzeugen mit geringem Vorfertigungsgrad dar.Aufbauend auf der Darstellung und Abgrenzung des Umformverfahrens werden relevante Prozessgrößen und deren Charakterisierung durch geeignete Ersatzversuche aus dem Stand der Wissenschaft recherchiert und bewertet. Zudem werden Möglichkeiten erörtert, die Ergebnisse der Ersatzversuche mit den Daten aus dem Umformverfahren zu vergleichen. Aus den technischen und wissenschaftlichen Defiziten ergibt sich die Zielsetzung und weitere Vorgehensweise dieser Arbeit.Zur Lösung der Problemstellung werden den identifizierten Prozessgrößen geeignete Ersatzversuche aus dem Stand der Technik zugeordnet bzw. neue Ersatzversuche entwickelt und im Rahmen eines modularen Versuchsstandes technisch umgesetzt. Zur Vorbereitung der experimentellen Analyse der ausgewählten Ersatzversuche werden Referenzversuche mit dem Umformverfahren innerhalb festgelegter Parametergrenzen durchgeführt. Bei der anschließenden Durchführung der Ersatzversuche wird vor allem die Verlässlichkeit der Ergebnisse berücksichtigt, indem die Anzahl der Versuche jeder Versuchsreihe an die Ergebnisauswertung angepasst wird.Durch die Modifikation des Umformverfahrens können die Ergebnisse der Ersatzversuche innerhalb eines stufenweise komplexer werdendes, empirischen Modelsmit denen des Referenzversuchs verglichen und bewertet werden. Die Charakterisierung der Prozesskraftkomponenten wird für vier faserbasierte Materialien durchgeführt,die teilweise mit einer polymeren Funktionsschicht ausgestattetsind.Abschließend werden die Ergebnisse dieser Arbeit zusammengefasst dargestellt und daraus folgende Forschungsansätze abgeleitet.The purpose of this thesis is to present a newly developed method to investigate thecomplexload situation during the deep-drawing of paperboard within suitable substitute tests and its validation withinan empirical model.Deep drawing with direct compression represents analternativefor the production of three-dimensional traysfrom natural, fiber-based materials with a low degree of prefabrication.Based on the definition and description of the deep-drawing process within the literature, relevant process forces and associated substitute tests are identifiedand discussed. In addition, approachesare discussed to compare the results of the substitute tests with the data from the deep-drawingprocess. The objective and further procedure of this thesisresults from the technical and scientific deficits.The approach of this thesisis it to present a new, modular testing rig based on the substitute test which were chosen from the literature or were newly developed.In preparation ofthe experimental analysis of the selected substitutetests, reference tests are carried out with the forming process within specified parameter limits. In the subsequent implementation of the substitutetests, the reliability of the results is consideredabove all by adapting the number of tests in each test series parallel to the evaluation of the results. By modifying the forming process, the results of the substitute tests can be compared and evaluated with those of the reference test within an empirical model that becomes progressively more complex. The characterization of the process force components iscarried out for four fiber-based materials, some of which are equipped with a polymer functional layer.Finally, the results of this work are summarized,and the following research approaches are derived from them

Analysis of Dominant Process Parameters in Deep-Drawing of Paperboard

The application of the wrinkle measuring method described in Müller et al. (2017) and the subsequent evaluation algorithm of a range of deep-drawn samples were used to determine the influences and interdependencies of blankholder force, tool temperatures, and drawing height on the formation of wrinkles in paperboard. The main influences were identified and quantitatively evaluated. For the given experimental space, a regression function was derived and validated in further experiments. It was shown that a quadratic regression was superior to the previously used linear regression. The findings were discussed and compared with the results of similar experiments from past publications. Special attention was given to the wrinkles formed and the resulting quality of the formed paperboard cups. The restrictions of the data acquisition from the measuring method that was used and limitations of the model were presented to demonstrate the reliability of the results

Evaluating the Factors Influencing the Friction Behavior of Paperboard during the Deep Drawing Process

Deep drawing of paperboard with rigid tools and immediate compression has only a small presence in the market for secondary packaging solutions due to a lack of understanding of the physical relations that occur during the forming process. As with other processes that deal with interactions between two solids in contact, the control of the factors that affect friction is important due to friction’s impact on runnability and process reliability. A new friction measurement device was developed to evaluate the factors influencing the friction behavior of paperboard such as under the specific conditions of the deep drawing process, which differ from the standard friction testing methods. The tribocharging of the contacting surfaces, generated during sliding friction, was determined to be a major influence on the dynamic coefficient of friction between paperboard and metal. The same effect could be examined during the deep drawing process. With increased contact temperature due to the heating of the tools, the coefficient of friction decreased significantly, but it remained constant after reaching a certain charging state after several repetitions. Consequently, to avoid ruptures of the wall during the forming process, tools that are in contact with the paperboard should be heated

New Method to Evaluate the Frictional Behavior within the Forming Gap during the Deep Drawing Process of Paperboard

To evaluate the influence of different normal forces and contact temperatures on the frictional behavior of paperboard during the deep drawing process, a new measurement punch was developed to measure the normal force, which induced the friction within the gap between the forming cavity and punch. The resulting dynamic coefficient of friction was calculated and reproduced via a new developed substitute test for the friction measurement device, which was first introduced in Lenske et al. (2017). The normal force within the forming gap during the deep drawing process was influenced by the blankholder force profile, the contact temperature, and the fiber direction. The friction measurements with the substitute test showed a strong dependency between the applied normal force and the dynamic coefficient of friction. Furthermore the frictional behavior was influenced by the contact temperature and the wrinkle formation

Analysis of Dominant Process Parameters in Deep-Drawing of Paperboard

The application of the wrinkle measuring method described in Müller et al. (2017) and the subsequent evaluation algorithm of a range of deep-drawn samples were used to determine the influences and interdependencies of blankholder force, tool temperatures, and drawing height on the formation of wrinkles in paperboard. The main influences were identified and quantitatively evaluated. For the given experimental space, a regression function was derived and validated in further experiments. It was shown that a quadratic regression was superior to the previously used linear regression. The findings were discussed and compared with the results of similar experiments from past publications. Special attention was given to the wrinkles formed and the resulting quality of the formed paperboard cups. The restrictions of the data acquisition from the measuring method that was used and limitations of the model were presented to demonstrate the reliability of the results

Analysis of Dominant Process Parameters in Deep-Drawing of Paperboard

The application of the wrinkle measuring method described in Müller et al. (2017) and the subsequent evaluation algorithm of a range of deep-drawn samples were used to determine the influences and interdependencies of blankholder force, tool temperatures, and drawing height on the formation of wrinkles in paperboard. The main influences were identified and quantitatively evaluated. For the given experimental space, a regression function was derived and validated in further experiments. It was shown that a quadratic regression was superior to the previously used linear regression. The findings were discussed and compared with the results of similar experiments from past publications. Special attention was given to the wrinkles formed and the resulting quality of the formed paperboard cups. The restrictions of the data acquisition from the measuring method that was used and limitations of the model were presented to demonstrate the reliability of the results