An explicit finite element model of the deep-drawing of paperboard has been developed
utilizing a custom yet simple material model which describes the anisotropy and plasticity
of paperboard. The model was verified with a variety of tests and was then utilized to compare
the punch force that was measured during the deep-drawing experiments to the
punch force that was calculated during the deep-drawing simulations. All material parameters
were calibrated based on individual experiments; thus, no parameter fitting was utilized
to match the experimental deep-drawing results. The model was found to predict the
experimental results with reasonable accuracy up to the point when wrinkling began to
dominate the material response. Since most failures during paperboard deep-drawing
occur before wrinkling begins to play a major role, this model can probably be utilized
to study and predict the failure of deep-drawn paperboard cups. The overall trends and
the effects of major process parameters are predicted by the model. The process parameters
that were varied and compared for both experiments and simulations were: blankholder
force, die temperature, and thickness. The model was utilized to discover that
friction of the blankholder and die have significant effects on the punch force and thus
the stress, implying that low-friction dies and blankholders can considerably reduce the
failure probability and thus also improve the quality of deep-drawn paperboard cups.
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