Micro-mechanical modeling of the paper compaction process

Double-roll compaction is a process to create extensible paper and paperboard suitable for replacing plastic in 3D forming applications. Understanding the macro- and micro-mechanisms governing the compaction process allows increasing the stretch potential while maintaining sufficient strength and bending stiffness. In this work, we approach the compaction process of paperboard with micro-mechanical methods featuring the unprecedented level of details otherwise inaccessible with currently available experimental tools. The loading scheme is based on experiments and continuum level simulations. The different levels of compaction and their continuous impact on the fibers’ geometry, void closures, and irreversible deformation of the fibers are thoroughly characterized. We find that the structural changes are concentrated in the fibers oriented within 30 degrees of the direction of compaction. The deformation accumulates primarily in the wall of the fibers in the form of irreversible strains. The spring-back effect beyond the compaction is negligible. For the first time, the role of normal and frictional fiber-to-fiber interactions in the compaction process is investigated and quantified. The frictional interaction between the fibers has a surprisingly low impact on the outcome of the compaction process, and the normal interaction between the fibers has a dominant response. The consequence of this finding is potentially limited impact of the surface modifications targeting the friction.
QC 20220331