A Computational Mechanics Model for the Brim Forming Process in Paperboard Container Manufacturing

The manufacturing process of brim forming in paperboard containers consists of taking a thin paperboard shell and forming a brim to provide additional stiffness to the structure. A paper cup is an example of such a structure manufactured at rates exceeding 300 units per minute. A realistic model for the manufacturing process is not available and the effects of process and material parameters are not well understood. In this study, a finite element model of this highly nonlinear problem is presented. The model takes into account the material orthotropy and nonlinear elastic-plastic behavior, die paperboard contact interaction during loading and unloading, and friction between the metal die and paperboard, die geometry, and environmental conditions. Model predictions of the force-displacement curve agree well with the experimentally observed results.