In this publication, the ultrasonic-assisted deep-drawing of fiber-based materials, whose implementation was presented in Löwe et al. (2016), was studied in detail. Methods were developed for measuring the properties of deep-drawn cups, including cup stability, shape deviation, and surface quality. The relationship between these properties and the process parameters were determined with a design of experiment, which allows the user to adjust the cup properties in order to optimize them.

In manufacturing processes, the quality of a product often depends on its surface, and careful control of surface properties is critical to meet customer requirements. A thin layer of polyethylene (PE) is applied to paperboard to increase barrier functionality and high optical quality of the product. For PE-coated paperboard, product quality inspection is performed at the end of the manufacturing process by taking a portion of the reel to the laboratory for quality inspection. These associated offline characterization methods are destructive and time consuming and are representative of only a small portion of the product. The overall goal of this thesis is to provide new methods to characterize the Surface properties of PE-coated paperboard. Specifically, to determine imaging techniques for measuring surface parameters that affect its barrier functionality and surface roughness. In this thesis, two methods for surface characterization of PE-coated paperboard are presented to quantify the two most important product-related quality parameters, i.e. barrier functionality and optical quality, which are affected by the presence of defects in the coating and by the surface roughness of the product, respectively. First, a full-Stokes imaging polarimeter (FSIP) is used to detect the presence of PE-coated material and to distinguish between coated and uncoated samples at the pixel level. Second, a three-dimensional scanning electron microscope (3D SEM) is employed to calculate the Surface roughness of PE-coated paperboard. These surface characterization techniques offer an advantage over the industry standard due to the high speed and non-contact nature of the measurement, while increasing the throughput of the sample surface parameters studied. A classification accuracy of 99, 74% is achieved using a FSIP to distinguish between PE- and non-PE-coated paperboard at pixel level. Using the 3D SEM technique to measure the topography of PE-coated samples results in a faster method that is comparable in accuracy to a chromatic confocal microscope (CCM). The surface roughness measured with the 3D SEM differs from the standard method by up to 6% and good agreement with statistical parameters is found. In general, surface analysis of PE-coated is often a complex and difficult task for imaging techniques and suitable methods need to be evaluated for their sensitivity to measure the desired surface parameters. The presented characterization techniques inspect larger areas of PE-coated paperboard compared to current industry standards. These methods provide a quantitative solution for surface characterization to inspect the surface parameters necessary to assure the product’s quality.

Gegenstand dieser Arbeit ist die Entwicklung einer Methode zur Charakterisierung der komplexen Belastungssituation beim Tiefziehen mit unmittelbarer Kompression von Karton innerhalb geeigneter Ersatzversuche und deren Validierung mit Hilfe eines empirischen Models. Das Tiefziehen mit unmittelbarer Kompression stellt eine Möglichkeitzur Herstellung von dreidimensionalen Hohlkörpern mit hohem Umformgrad aus naturfaserbasierten, flächigen Halbzeugen mit geringem Vorfertigungsgrad dar.Aufbauend auf der Darstellung und Abgrenzung des Umformverfahrens werden relevante Prozessgrößen und deren Charakterisierung durch geeignete Ersatzversuche aus dem Stand der Wissenschaft recherchiert und bewertet. Zudem werden Möglichkeiten erörtert, die Ergebnisse der Ersatzversuche mit den Daten aus dem Umformverfahren zu vergleichen. Aus den technischen und wissenschaftlichen Defiziten ergibt sich die Zielsetzung und weitere Vorgehensweise dieser Arbeit.Zur Lösung der Problemstellung werden den identifizierten Prozessgrößen geeignete Ersatzversuche aus dem Stand der Technik zugeordnet bzw. neue Ersatzversuche entwickelt und im Rahmen eines modularen Versuchsstandes technisch umgesetzt. Zur Vorbereitung der experimentellen Analyse der ausgewählten Ersatzversuche werden Referenzversuche mit dem Umformverfahren innerhalb festgelegter Parametergrenzen durchgeführt. Bei der anschließenden Durchführung der Ersatzversuche wird vor allem die Verlässlichkeit der Ergebnisse berücksichtigt, indem die Anzahl der Versuche jeder Versuchsreihe an die Ergebnisauswertung angepasst wird.Durch die Modifikation des Umformverfahrens können die Ergebnisse der Ersatzversuche innerhalb eines stufenweise komplexer werdendes, empirischen Modelsmit denen des Referenzversuchs verglichen und bewertet werden. Die Charakterisierung der Prozesskraftkomponenten wird für vier faserbasierte Materialien durchgeführt,die teilweise mit einer polymeren Funktionsschicht ausgestattetsind.Abschließend werden die Ergebnisse dieser Arbeit zusammengefasst dargestellt und daraus folgende Forschungsansätze abgeleitet. / The purpose of this thesis is to present a newly developed method to investigate thecomplexload situation during the deep-drawing of paperboard within suitable substitute tests and its validation withinan empirical model.Deep drawing with direct compression represents analternativefor the production of three-dimensional traysfrom natural, fiber-based materials with a low degree of prefabrication.Based on the definition and description of the deep-drawing process within the literature, relevant process forces and associated substitute tests are identifiedand discussed. In addition, approachesare discussed to compare the results of the substitute tests with the data from the deep-drawingprocess. The objective and further procedure of this thesisresults from the technical and scientific deficits.The approach of this thesisis it to present a new, modular testing rig based on the substitute test which were chosen from the literature or were newly developed.In preparation ofthe experimental analysis of the selected substitutetests, reference tests are carried out with the forming process within specified parameter limits. In the subsequent implementation of the substitutetests, the reliability of the results is consideredabove all by adapting the number of tests in each test series parallel to the evaluation of the results. By modifying the forming process, the results of the substitute tests can be compared and evaluated with those of the reference test within an empirical model that becomes progressively more complex. The characterization of the process force components iscarried out for four fiber-based materials, some of which are equipped with a polymer functional layer.Finally, the results of this work are summarized,and the following research approaches are derived from them.

Paperboard is produced in a large and complex process where many parameters can affect its quality. The common methods of analysing paperboard quality are through traversing point-like sensors that only measure a very small fraction of the produced paperboard. Holmen Iggesund Paperboard has installed an IR-camera that measures the entire paperboard web and is looking for a tool to assess paperboard quality variation based on these measurements. The purpose of this thesis work is to develop such a tool. This was done through developing a user-friendly computer application (app) IR-measurement Analysis (IRMA). The app is designed to help the process engineers of Iggesunds mill assess the paperboard variability, which strongly correlates with its quality. The quality improvements of paperboard mainly concern eliminating irregularities in thickness, grammage, and moisture. In IRMA, theuser can prepare data, perform statistical analyses, execute a frequency analysis through Fast Fourier Transform and then compare the frequency peaks with the frequencies of possible sources for periodic process variation, for example rolls. Correlating frequency peaks and roll frequencies can indicate issues with rolls and make process engineers at the mill aware of maintenance needs. IRMA have been tested at the mill and these tests have indicated that IRMA can be beneficial in the process engineer’s daily quality control measures. Furthermore, a manual has been written and the process engineers will be thoroughly educated in the use of IRMA.

The objectives of the thesis were to find the mechanisms that govern compression failures in paperboard and to find the link between manufacturing process and paperboard properties. The thesis also investigates two different test methods and evaluates how suitable they are for paperboard grades. The materials are several commercial board grades and a set of hand-formed dynamic sheets that are made to mimic the construction of commercial paperboard. The method consists of mounting a stereomicroscope on a short-span compression tester and recording the compression failure on video, long-span compression testing and standard properties testing. The observed failure modes of paperboard under compression were classified into four categories depending on the appearance of the failures. Initiation of failure takes place where the structure is weakest and fiber buckling happens after the initiation, which consists of breaking of fiber-fiber bonds or fiber wall delamination. The compression strength is correlated to density and operations and raw materials that increase the density also increases the compression strength. Short-span compression and Long-span compression are not suitable for testing all kinds of papers; the clamps in short-span give bulky specimens an initial geometrical shape that can affect the given value of compression strength. Long-span compression is only suitable for a limited range of papers, one problem with too thin papers are low wavelength buckling.

Deep drawn shapes with orthogonal wall components are usually evaluated by shape accuracy and visual quality. There have been only a few investigations on the stability of such structures; however, the effect of the wrinkles on the stability of the wall is important for packaging applications and can support the shape accuracy. This paper focuses on the influences of process parameters on the stability of orthogonal walls of shapes produced by deep drawing with rigid tools and immediate compression. The wall stability was evaluated by tensile testing orthogonal to the direction of the wrinkles. The stability distribution was characterized with regard to the drawing height, and a comparison was made between the two different materials. The wall stability decreased with increases in the forming height. Furthermore, a blank holder force design and z-directional compression level improved the wall stability. Together with an elevated moisture content of the material and thermal energy supply that delivered two to three times higher resistance against wrinkle extension, these effects drastically improved the wall stability.

The Japanese paper and paperboard industry has grown to be one of the largest in the world. It manufactures a range of products for sale primarily within Japan, and consumes organic fibre for these products from dispersed domestic and foreign forests, plantations and cities. This dissertation examines the links between the development and structure of the industry and its use of papermaking fibre. It takes a political ecology perspective and uses an industrial structure/consumption-production chain approach to show how the industry’s development and structure continue to depend on company control over fibre flows and the restructuring of products, product distribution and manufacture, the fibre supply chain and fibre resources. As with the modern global paper/board industry, the recent growth of the Japanese industry has been characterised by cycles of capacity expansion, market collapse, excess capacity and low prices and profits. Manufacturers and general trading companies involved in the industry have tried to support growth in the use of paper/board and counter these cycles by restructuring production, distribution, ownership and fibre supply. This restructuring helps protect the flow of fibre through the industry and concentrated it in particular companies. Obtaining increasing quantities of suitably-priced fibre has been at the base of the industry’s development.

The Japanese paper and paperboard industry has grown to be one of the largest in the world. It manufactures a range of products for sale primarily within Japan, and consumes organic fibre for these products from dispersed domestic and foreign forests, plantations and cities. This dissertation examines the links between the development and structure of the industry and its use of papermaking fibre. It takes a political ecology perspective and uses an industrial structure/consumption-production chain approach to show how the industry’s development and structure continue to depend on company control over fibre flows and the restructuring of products, product distribution and manufacture, the fibre supply chain and fibre resources. As with the modern global paper/board industry, the recent growth of the Japanese industry has been characterised by cycles of capacity expansion, market collapse, excess capacity and low prices and profits. Manufacturers and general trading companies involved in the industry have tried to support growth in the use of paper/board and counter these cycles by restructuring production, distribution, ownership and fibre supply. This restructuring helps protect the flow of fibre through the industry and concentrated it in particular companies. Obtaining increasing quantities of suitably-priced fibre has been at the base of the industry’s development.

Deep drawing of paperboard with rigid tools and immediate compression has only a small presence in the market for secondary packaging solutions due to a lack of understanding of the physical relations that occur during the forming process. As with other processes that deal with interactions between two solids in contact, the control of the factors that affect friction is important due to friction’s impact on runnability and process reliability. A new friction measurement device was developed to evaluate the factors influencing the friction behavior of paperboard such as under the specific conditions of the deep drawing process, which differ from the standard friction testing methods. The tribocharging of the contacting surfaces, generated during sliding friction, was determined to be a major influence on the dynamic coefficient of friction between paperboard and metal. The same effect could be examined during the deep drawing process. With increased contact temperature due to the heating of the tools, the coefficient of friction decreased significantly, but it remained constant after reaching a certain charging state after several repetitions. Consequently, to avoid ruptures of the wall during the forming process, tools that are in contact with the paperboard should be heated.

Deep drawn shapes with orthogonal wall components are usually evaluated by shape accuracy and visual quality. There have been only a few investigations on the stability of such structures; however, the effect of the wrinkles on the stability of the wall is important for packaging applications and can support the shape accuracy. This paper focuses on the influences of process parameters on the stability of orthogonal walls of shapes produced by deep drawing with rigid tools and immediate compression. The wall stability was evaluated by tensile testing orthogonal to the direction of the wrinkles. The stability distribution was characterized with regard to the drawing height, and a comparison was made between the two different materials. The wall stability decreased with increases in the forming height. Furthermore, a blank holder force design and z-directional compression level improved the wall stability. Together with an elevated moisture content of the material and thermal energy supply that delivered two to three times higher resistance against wrinkle extension, these effects drastically improved the wall stability.