Analytical Homogenization Approach for Double-Wall Corrugated Cardboard Incorporating Constituent Layer Characterization

This work presents an analytical homogenization model developed to predict the tensile and bending behavior of double-wall corrugated cardboard. The proposed approach replaces the complex three-dimensional geometry, composed of five paper layers, with an equivalent two-dimensional homogenized plate. Based on lamination theory and enhanced by sandwich structure theory, the model accurately captures the orthotropic behavior of the material. To achieve this objective, three configurations of double-wall corrugated cardboard were investigated: KRAFT LINER (KL), DUOSAICA (DS), and AUSTRO LINER (AL). A comprehensive experimental characterization campaign was conducted, including physical analyses (density measurement, SEM imaging, and XRD analysis) and mechanical testing (tensile tests), to determine the input parameters required for the homogenization process. The proposed model significantly reduces geometric complexity and computational cost while maintaining excellent predictive accuracy. Validation was performed by comparing the results of a 3D finite element model (ANSYS-19.2) with those obtained from the homogenized H-2D model. The differences between both approaches remained systematically below 2%, confirming the ability of the H-2D model to accurately reproduce the axial and flexural stiffnesses of double-wall corrugated cardboard. The methodology provides a reliable and efficient framework specifically dedicated to the mechanical analysis and optimization of corrugated cardboard structures used in packaging applications.