No abstract

The folding carton is a widely used packaging solution. Recent European Union packaging legislation has forced carton manufacturers to use lighter-weight grades of carton board. This typically results in a reduction in board stiffness, which can lead to decreased process efficacy or even prevent successful processing. In order to overcome this, end-users lower production rates and fine-tune packaging machine settings for each pack and material. This trial-and-error approach is necessary because the rules relating machine set-up to pack design and material properties are not generally well known. The present study addresses this fundamental issue through the creation of a finite-element computer simulation of carton processing. Mechanical testing was performed to ascertain the key mechanical properties of the carton walls and creases. The carton model was validated against the experimental results and was then subjected to the machine-material interactions that take place during complex packaging operations. The overall approach was validated and the simulation showed good agreement with the physical system. The results of the simulation can be used to determine guidelines relating machine set-up criteria to carton properties. This will improve responsiveness to change and will ultimately allow end-users to process thinner lighter-weight materials more effectively.

In response to recent European Union (EU) regulations on packaging waste, the packaging industry requires greater fundamental understanding of the machine-material interactions that take place during packaging operations. Such an understanding is necessary to handle thinner lighter-weight materials, specify the material properties required for successful processing and design right-first-time machinery. The folding carton industry, in particular, has been affected by the new legislation and needs to realize the potential of computational tools for simulating the behaviour of packaging materials and generating the necessary understanding. This paper describes the creation and validation of a detailed finite element model of a carton during a common packaging operation. The model is applied here to address the problem of carton buckling. The carton was modelled using a linear elastic material definition with non-linear crease behaviour. Air inrush suction, which is believed to cause buckling, was quantified experimentally and incorporated using contact damping interactions. The results of the simulation are validated against high-speed video of carton production. The model successfully predicts the pattern of deformation of the carton during buckling and its increasing magnitude with production rate. The model can be applied to study the effects of variation in material properties, pack properties and machine settings. Such studies will improve responsiveness to change and will ultimately allow end-users to use thinner, lighter-weight materials in accordance with the EU regulations.

The wrist is a complex joint and the factors governing its behaviour are poorly understood. A hypothesis that the movement of the carpal bones could be predicted using a minimum energy principle was tested. Carpal bones were dissected from a cadaveric forearm and their shapes were laser-digitized to obtain three-dimensional computer models. A computer program was created to measure contact area between neighbouring articular surfaces and to maximize this quantity by adjusting the six degrees of freedom of the bone models. This procedure was performed for 1.0 degree increments of rotation applied to the capitate bone up to 20 degrees of ulnar and 10 degrees of radial deviation. The model correctly predicted certain aspects of the complex behaviour of the carpal bones. The results for the scaphoid in particular displayed characteristics in common with known behaviour of this bone. During 20 degrees of unlar deviation and 10 degrees of radial deviation, the bone demonstrated 11.3 degrees of extension and 9.4 degrees of flexion respectively. The novelty of the study lay in the fact that the model did not rely upon ligamentous constraints. The results are encouraging, considering the only information used by the algorithm was the shape of the articular surfaces.

Finger design automation for grippers is one of the areas of highest interest for robot industries. The few studies that have been carried out in the finger design automation research area are limited to objects with specific geometrical properties (e.g. polyhedral). This paper introduces the Generic Automated Finger Design (GAFD) method that contains the essential key processes for automatic design of reliable fingers. The proposed method is implemented on two geometrically complex workpieces and appropriate fingers are designed. The results are discussed in detail and benchmarked against existing approaches.