Case study 1

Optimisation of the fracture properties using an FEM calculation

 

Starting situation

Ridges that support the fitting of the lid to the ice cream tub were attached to the lid of ice-cream packaging to improve the capping and secure the edges of the tub and the lid when the lid is fully closed.

During production it turned out that deformation of the ridges always occurred, leading to subsequent fractures. There is therefore a risk of the ridges getting into the ice cream box and its contents as foreign objects.

 

Industry

Dairy products

Strategy/reason

Unwanted deformation and fractures

Task

To geometrically optimise the support ridges/insertion aids on the lid in order to prevent deformation and fractures.

Implementation

To find the optimal solution for this task as quickly as possible, we have performed a computer-assisted strength calculation (Finite element method, abbreviation FEM).

Using this method, we were able to simulate various potential solutions in advance and compare the resulting deformation and fracture properties. The geometry of the edges was changed in several optimisation loops until a minimal load situation was achieved. The theoretically determined optimum solution was then incorporated in the series production tool.

To find the optimal solution for this task as quickly as possible, we have performed a computer-assisted strength calculation (Finite element method, abbreviation FEM).

Using this method, we were able to simulate various potential solutions in advance and compare the resulting deformation and fracture properties. The geometry of the edges was changed in several optimisation loops until a minimal load situation was achieved. The theoretically determined optimum solution was then incorporated in the series production tool.

 

Result

The mechanical load of the edges was reduced significantly by means of the geometric optimisation. The edges were expected to have significantly improved fracture properties due to the significantly reduced stress and deformation. The theoretical findings were verified by 100% in the subsequent implementation in practice. Comprehensive load and drop tests at the customer's confirmed the previously calculated improvements to the full extent.

Customer benefit

The optimal solution was determined from many different variants by using the FEM calculation. The result could be calculated without expensive tool modifications. The implementation time was reduced drastically compared to classic, practical trial and error tool optimisation.

Our customers will receive an optimum solution within the shortest possible implementation time with minimal modification costs. Product safety has been increased significantly within the filling and logistics processes.

Intensified description of the deformation result of the starting situation

Intensified description of the deformation result of the starting situation

Result of the final stage of optimisation

Result

Improvement to

  • Fracture properties
  • Implementation time
  • Production safety