Virtual Drop Test Analysis of Corrugated Box Packaging for Material Handling

This research paper investigates the impact behaviour of corrugated boxes through drop tests, employing the 3D Experience platform for modelling and simulation. Various thicknesses of corrugated boxes (1 mm, 2 mm, 4 mm, and 6 mm) are analysed by dropping them from a height of 1 m. The structural package app is utilized for model creation, while pre-processing is conducted using structural model creation and mechanical scenario creation apps. The study incorporates wood and aluminium blocks within the box for testing, considering their respective yield strengths. Additionally, to accurately represent the material properties, composite modelling techniques are employed. This study aims to enrich our understanding of corrugated board behaviour under impact conditions and optimize its design for enhanced mechanical performance. Adding thickness to a component can indeed help reduce stress during a drop test, but it is not the only factor to consider. Increasing thickness can distribute forces more evenly and provide greater structural integrity, thereby reducing stress concentrations. However, other design features, such as changing material properties, can also play a significant role in stress reduction. It is essential to analyse the specific requirements and constraints of the drop test scenario to determine the most effective design modifications. The maximum Von Mises stress for corrugated cardboard box drops from 4 × 106 Pa in Case I to 1.41 × 106 Pa in Case IV, reflecting a reduction of 64.75 %. This highlights the significant stress reduction achieved with increasing thickness. The observed decrease in stress levels with thickness underscores the importance of considering material properties, stress concentrations, impact response, structural integrity, and design optimization strategies in developing robust and reliable components for drop test applications. Major Findings: The primary discovery is that augmenting the material's thickness markedly reduces Von Mises stress, thereby improving load-bearing capacity and structural integrity. Furthermore, employing sophisticated simulations such as virtual drop tests enhance design precision by detecting potential failure points.