Forming Process Simulation

Due to rising demands on packaging solutions because of the changing consumer behavior both the manufacturers of packaging machines and the operators are halted to optimize their processes and tools. To reduce the high expense of experiments often simulations are used. Currently, the Finite-Element-Method (FEM) is used for simulating strain scenarios. The advantages of the FEM are opposed by a few disadvantages and problems when simulating films because the FEM is there stretched to its limits. Here the classical FEM gets fast unstable because of creasing and large deformations.

Additionally, the FEM is able to handle nonlinearities and complex geometries only partly. Furthermore specific effects, like the crack initiation and –propagation are still a problem.

Innovative simulation methods, as they are used in the textile industry, medical engineering and computer graphics, could give approaches to a development of new simulation tools for the packaging industry. In particular, the particle simulation should be mentioned here. The usage of this simulation method promises the overcoming of the above outlined limits of the FEM. As a result, an integrated investigation of complex form processes, for example forming shoulders, is possible. Despite that, there is a large need for research and development for a packaging industry specific solution. A contribution to this is made with the present research project.

Especially for small and medium-sized businesses the development of new approaches is related to a high economical risk, but also to a large benefit. The aim of the project is to identify potentialities, limits and development needs of an innovative particle based simulation method. Afterwards it is planned to develop an application-specific simulation tool within a following research project.