Optimization of the dimensional stability of paper‐based sandwich panels during the pressing process using design of experiments.

In this contribution, the causes leading to the undesired unevenness on the exterior surface of a paper‐based sandwich structure during the manufacturing process are investigated. This provides insight into the manufacturing parameters that need to be adjusted to reduce this waviness. A finite element model of the pressing process is developed in the commercial software ABAQUS and then used to analyze the formation of the surface unevenness. The sandwich structure adopted in the model consists of a decorative layer, an intermediate layer, a corrugated core and a bottom layer. In particular, the core has a sinusoidal structure with various geometry parameters, which are adjusted in the model to investigate the effect on the waviness of the top surface. The results of the quasi‐static process simulation correlate well with the experimental results. A subsequent parameter study based on the design of experiments (DoE) shows the relationship between the material parameters of the intermediate/bottom layer and the resulting waviness. [ABSTRACT FROM AUTHOR]