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Laboratory tests were conducted on innovatively designed corrugated board packaging under random vertical vibrations. The innovative designs had reinforced critical corner zones and lid–base interfaces through geometry modifications that increased double-wall regions. A total of 25 packaging variants, differentiated in structure, layer configuration (three-layer and five-layer boards), and surface finish (with and without coatings) were evaluated. The experimental study included box compression tests (BCT) and random vibration tests according to international standards (ISO 12048:1994 and ISO 13355:2016), simulating storage and transportation conditions. All packages were assessed before and after random vibration tests to determine the influence of dynamic loads on structural load-bearing capacity. Unlike previous studies limited to static testing, this work evaluated combined vibration and compression effects under standardized dynamic loading conditions for packaging with relatively low probability of being dropped. Furthermore, it was shown that the innovative design of corrugated board transport packaging presents higher static load capacity after random vibration testing in terms of column compression strength, indicating that no reduction in box strength was observed during simplified transport simulation under pure one-direction dynamic loading. The findings contribute to the optimization of high-durability packaging solutions tailored for the growing demands of complex logistics chains.

When producing packaging from corrugated board, material weakening often occurs both during the die-cutting process and during printing. While the analog lamination and/or printing processes that degrade material can be easily replaced with a digital approach, the die-cutting process remains overwhelmingly analog. Recently, new innovative technologies have emerged that have begun to replace or at least supplement old techniques. This paper presents the results of laboratory tests on corrugated board and packaging made using both analog and digital technologies. Cardboard samples with digital and analog creases are subject to various mechanical tests, which allows for an assessment of the impact of creases on the mechanical properties of the cardboard itself, as well as on the behavior of the packaging. It is proven that digital technology is not only more repeatable, but also weakens the structure of corrugated board to a much lesser extent than analog. An updated numerical model of boxes in compression tests is also discussed. The effect of the crushing of the material in the vicinity of the crease lines in the packaging arising during the analog and digital finishing processes is taken into account. The obtained enhanced computer simulation results closely reflect the experimental observations, which prove that the correct numerical analysis of corrugated cardboard packaging should be performed with the model taking into account the crushing.

Corrugated cardboard boxes are generally used in modern supply chains for the handling, storage, and distribution of numerous goods. These packages require suitable strength to maintain adequate protection within the package; however, the presence and configuration of any cutouts on the sidewalls significantly influence the packaging costs and secondary paperboard waste. This study aims to evaluate the performance of CCBs by considering the influence of different cutout configurations of sidewalls. The compression strength of various B-flute CCB dimensions (200 mm, 300 mm, 400 mm, 500 m, and 600 mm in length, with the same width and height of 300 mm), each for five cutout areas (0%, 4%, 16%, 36%, and 64%) were experimentally observed, and the results were compared with the McKee formula for estimation. The boxes with cutout areas of 0%, 4%, 16%, 36%, and 64% showed a linear decreasing tendency in compression force. A linear relationship was found between compression strength and an increase in cutout sizes. Packages with 0% and 4% cutouts did not show significant differences in compression strength (p < 0.05). Furthermore, this study shows a possible way to modify the McKee estimation for such boxes after obtaining empirical test data since the McKee formula works with a relatively high error rate on corrugated cardboard boxes with sidewall cutouts. Utilizing the numerical and experimental results, a favorable estimation map can be drawn up for packaging engineers to better manage material use and waste. The results of the study showed that the McKee formula does not appropriately estimate the box compression strength for various cutout sizes in itself.

The finite element method is a widely used numerical method to analyze structures in virtual space. This method can be used in the packaging industry to determine the mechanical properties of corrugated boxes. This study aims to create and validate a numerical model to predict the compression force of corrugated cardboard boxes by considering the influence of different cutout configurations of sidewalls. The types of investigated boxes are the following: the width and height of the boxes are 300 mm in each case and the length dimension of the boxes varied from 200 mm to 600 mm with a 100 mm increment. The cutout rates were 0%, 4%, 16%, 36%, and 64% with respect to the total surface area of sidewalls of the boxes. For the finite element analysis, a homogenized linear elastic orthotropic material model with Hill plasticity was used. The results of linear regressions show very good estimations to the numerical and experimental box compression test (BCT) values in each tested box group. Therefore, the numerical model can give a good prediction for the BCT force values from 0% cutout to 64% cutout rates. The accuracy of the numerical model decreases a little when the cutout rates are high. Based on the results, this paper presents a numerical model that can be used in the packaging design to estimate the compression strength of corrugated cardboard boxes.

The impact of perforation patterns on the compressive strength of cardboard packaging is a critical concern in the packaging industry, where optimizing material usage without compromising structural integrity is essential. This study aims to investigate how different perforation designs affect the load-bearing capacity of cardboard boxes. Utilizing finite element method (FEM) simulations, we assessed the compressive strength of packaging made of various types of corrugated cardboards, including E, B, C, EB, and BC flutes with different heights. Mechanical testing was conducted to obtain accurate material properties for the simulations. Packaging dimensions were varied to generalize the findings across different sizes. Results showed that perforation patterns significantly influenced the compressive strength, with reductions ranging from 14% to 43%, compared to non-perforated packaging. Notably, perforations on multiple walls resulted in the highest strength reductions. The study concludes that while perforations are necessary for functionality and aesthetics, their design must be carefully considered to minimize negative impacts on structural integrity. These findings provide valuable insights for designing more efficient and sustainable packaging solutions in the industry.

This article presents a modified configuration of the box compression test (BCT), which reflects the actual behavior of the vegetable or fruit trays during transport and storage. In traditional load capacity tests, trays are treated as classic transport boxes, i.e., they are compressed between two rigid plates, which does not take into account the specific geometry of this type of packaging. Both the boundary conditions and the loads acting on the tray were modified. The paper presents the concept of a new test, as well as numerical models and a sensitivity analysis of the modified BCT to the basic geometrical dimensions of the tray. The conducted research clearly shows that the proposed configuration of the load-bearing capacity test of a tray is closer to the actual operation of the packaging. As a result, most of the parameters that are not active under the conditions of the classical BCT become more important in the new configuration, which corresponds to the observations on the real performance of the packaging.

Packaging made from corrugated cardboard is a widely used solution in modern supply chains for the handling, storage and distribution of goods. These packages are required to maintain adequate protection conditions; however, in many cases, the cardboard box dimensions, handles and/or ventilation holes, quality and their configuration could compromise its protection strength. This study observes and evaluates the performance of corrugated cardboard boxes made with B-flute boards by considering different cutout sizes from the side walls (0%, 20%, 40%, 60% and 80%) in various box length–width ratios of 200 mm, 300 mm, 400 mm, 500 mm and 600 mm in length and a constant 300 mm width and height. Box compression tests were performed in a laboratory, and results were compared with mathematical statistics. In each cutout case, the maximum compression force was observed with the box with dimensions of 400 × 300 × 300 mm. The measurement results showed that the 1.33 length-to-width ratio has the best maximum compression force result. The statistical tests showed that there is no significant difference between the 0% and 20% cutout groups.

This study experimentally and numerically investigated the overall buckling behavior of steel box column components. Two box section specimens were fabricated for axial compression tests. Prior to the tests, the material properties, initial geometric imperfections and residual stress were measured. In addition, an extended parameter analysis was conducted using a finite element model validated by experimental results to evaluate the impact of geometric defects and residual stresses on the bearing capacity of unstiffened and stiffened box section columns. A novel column curve was proposed based on massive datasets of parametric models. The short and long column specimens exhibited typical strength failure and buckling failure modes, respectively. The initial geometric imperfections and residual stresses slightly reduced the buckling strength from the models, with a maximum reduction in buckling strength owing to initial geometric imperfections of 5.2% and that owing to residual stresses of 6.52%. The unstiffened and stiffened box columns have the same stability coefficient when the slenderness ratio is the same. Additionally, the ultimate load capacity calculation formula for stiffened box columns proposed in this paper averages 2.20% higher than Class C curves in JTG D64-2015, lies between Japanese and U.S. codes, and demonstrates good accuracy.

In order to investigate the relationship between the strain of prestressed concrete girders under fatigue loading and the corrosion degree of prestressed steel reinforcements, four 12.4-m-long large-size post-tensioned prestressed concrete box girders were designed and fabricated in this study, and prestressed steel reinforcements were corroded at different degrees by the Electric Accelerated Corrosion Method. The same equal-amplitude loads were used during fatigue loading. The relationship between the strain of different materials (strains of the plain reinforcements and prestressed steel reinforcements, as well as concrete strains in compression zones) and the corrosion degree was investigated. Then, the calculation method for the cumulative residual strain of concrete in the compression zone of the test beam was obtained. The test results show the following: the strains of the test beams under different corrosion degrees all show a three-stage development law; the ratio of the strain amplitude of the prestressed steel reinforcement to that of the regular steel reinforcement during fatigue loading basically stays in the range of 0.65–0.75, and the ratio rises with the corrosion degree of the prestressed steel reinforcement; the increase in strain of the compressed concrete is due to the accumulation of the residual strain of the concrete, and the increase in material strain is almost directly proportional to the growth of corrosion degree under the same fatigue load; the calculated values of the accumulated residual strain of the concrete agree well with the test values and satisfy the accuracy requirements of engineering.

The aeolian sand-box backfilling method proves effective for environmentally friendly coal extraction in northwestern regions, including Xinjiang. This study investigated the geomechanical characteristics of aeolian sand-box backfill material and its control effects on overlying strata through indoor experiments, mechanical analysis, and numerical simulations. Uniaxial compression tests on models with varying mesh sizes, wire diameters, and dimensions revealed that larger mesh sizes and wire diameters increased the bearing capacity of the aeolian sand-box backfill material, while increasing dimensions had the opposite effect. A mechanical analysis of the metal mesh box deformation produced equations describing its restraining force. Subsequent experiments and simulations on models of different dimensions consistently demonstrated the material’s mechanical properties, with stress-displacement curves closely aligned. 3DEC5.2 software simulations highlighted the effectiveness of aeolian sand-box backfill material in controlling displacement and stress variations in goaf areas. Notably, smaller-sized backfill material exhibited a more pronounced impact on controlling overlying strata displacement and stress development.