Available online at ScienceDirect. Procedia Engineering 174 (2017 )

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1 Available online at ScienceDirect Procedia Engineering 174 (2017 ) th Global Congress on Manufacturing and Management, GCMM 2016 Design and Analysis of Cushioning Packaging for Home Appliances Gui Kun*, Wang Xi a Department of Transportation Planning and Management,Jilin University,Changchun,130025,China b Institute of Economic Research,Jilin Academy of Social Sciences Institute,Changchun,130033,China Abstract This research addresses the problem ofstudying how to design the packing liner of the flat TV and do safety inspection. According to the five step of cushion packaging design method to Select appropriate cushion liner. The finite element software ABAQUS is used to establish the simulation model and Element mesh is divided, combined with the explicit dynamics theory and elastic potential energy and time of flat panel TV striking the ground, to buffer gasket stress analysis and strength check. Through the simulation analysis, flat TV landing impact stress is far less than the maximum stress of liner can bear. The liner in the delivery process has a better protective effect and is able to reuse. This study can solve the problem of waste corrugated paperboard of the past and improve resource utilization The Authors. Published by Elsevier by Elsevier Ltd. Ltd. This is an open access article under the CC BY-NC-ND license ( Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management. Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management Keywords: cushion liner; polystyrene foam; five-step packaging development method; packing dynamics; stress analysis 1. Introduction In recent years, the proportion of logistics packaging is more and more valued in the logistics cost. In the home appliance packaging industry, corrugated and honeycomb paperboard material has been widely used for packaging home appliance products[1-3], these packaging materials must have good cushioning properties, can play a protective role in the process of transportation. Domestic and foreign scholars have made a lot of research on the cushioning properties of the packaging materials such as paper pulp molding. Xu Jie[4] explored the cushioning material properties and the development of home appliances cushioning packaging. Based on the experience analogy method and the finite element method, the six step design method of paper pulp molding buffer support was proposed by Dai Hong-min[5]. Won-Jin Kim and others[6-8] using MATLAB and model simulation technology to study the cushioning properties of foam and corrugated board. The development of computer in the field of wide * Corresponding author. Tel.: address: @qq.com The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license ( Peer-review under responsibility of the organizing committee of the 13th Global Congress on Manufacturing and Management doi: /j.proeng

2 Gui Kun and Wang Xi / Procedia Engineering 174 ( 2017 ) application and software technology, has further promoted the development of packaging dynamics [9-10], so that the focus of its research is more focused on the multi degree of freedom and nonlinear buffer system. Development of transistor technology has promoted the TV to the LCD flat, the packaging safety problem of flatpanel TVs have become the focus of research. This paper mainly carries on the design research of the flat TV's logistics package cushioning pad, five step design method that consider the packing dynamics and simulation results as the primary consideration is adopted, According to the stress curve of the material, select the appropriate buffer pad, three dimension imitation design of cushioning pad is simulate by CATIA software, and using the finite element software ABAQUS to do stress analysis and strength test, so that the choice of buffer material is more reasonable. 2. Selection of cushion liner based on five steps 2.1. Determine the circulation environment For the logistics distribution of flat TV, the vibration in the drop impact and transportation is the main flow environment. In the process of flat screen television transport will often occur horizontal and vertical impact, the impact of either vertical or horizontal, they can be converted to the equivalent of the acceleration of falling height. It can be seen that the equivalent drop height is very scientific and convenient to consider the impact resistance of packaging. Therefore, in the process of research, the design of the circulation environment can be summed up to determine the drop height of the packaging. At present, most of the cushioning packaging design according to the national standard of China ( GB/T package transport package drop test method and GB/T packaging transport packages compilation of performance test program for quantitative data )to do drop test, passing this test is qualified, so the test height of the test can also be used as a buffer package design drop height. In real life, the distribution mode of flat-panel TV is mainly artificial delivery. So that this paper considers the height of the human wrist from the ground, the effects of straps and cushion thickness, etc. The final ideal drop height is 250mm Determine the vulnerability of the product Products with poor packaging in the circulation process, have rupture, deformation, failure and other phenomena, resulting in the loss of product value, known as damage. If the amount of value is used to describe the extent of the damage, that is fragility[11]. The fragility is a reflection of the mechanical properties of the product itself, which is the ability of the product to resist dynamic shock when it is subjected to shock or vibration. When the impact force on the product exceeds its value, the structure of the product will be damaged or invalid. In order to ensure the safety of the product, it should carry out a reasonable cushioning package and below its fragility. In this paper, through the inquiry of the United States military standards, the United Kingdom comprehensive protection manual and the Japanese defense agency standard, after a comprehensive analysis, the final calculation of the fragility of the flat panel TV is G= Choose appropriate buffer pad After investigation, the average weight of 42 inch TV is about 15kg, taking the quality of the distribution equipment and the overall safety into account, the average quality of flat TV is 20kg. Through the circulation environment and the vulnerability of products identified by the above, the fragility of the flat panel TV is G=70, equivalent drop height is 250mm. products landing is commonly under the surface, so the bottom area of about m 2. The maximum stress of the liner is: GW m 225 MPa (1) A 0.6 m In the formula: is the calculation of the maximum stress for the liner, G is the fragility, W is the flat panel TV gravity, A is its lower surface area. Refer to the relevant charts, and the product is a polystyrene foam,. The

3 906 Gui Kun and Wang Xi / Procedia Engineering 174 ( 2017 ) density is g/cm3 and the buffer factor is C = The thickness of the liner is calculated as: CH h 9.3( mm) (2) G 70 In the formula: h is the thickness of the pad, C is the buffer factor, H is the drop height, G is the fragility of the product. 3. Simulation experiment of liner ABAQUS finite element software is powerful and widely used, can solve the nonlinear problem which is very complicated, a rich pool of cells allows it to simulate any geometry and it has a variety of types of material model library. In the nonlinear analysis, the ABAQUS can automatically select the appropriate load increment and the convergence limit, and adjust it to obtain the accurate solution. There are two main solver:abaqus / Standard and ABAQUS / Explicit, in ABAQUS software. It also contains a comprehensive support solver before processing the graphical user interface, ABAQUS / CAE, and some corresponding modules for some special problems. Because of the excellent simulation and analysis capability and reliability of ABAQUS software, it has been adopted by more and more countries and enterprises in various fields Establishment of model The bottom surface of the flat panel TV is mainly exposed to the ground, so the force of cushion liner when the flat panel TV is falling is mainly considered. The ground is considered as a rigid body, and the flat TV is regarded as a large elastic body of Young's modulus. After checking the relevant information[12], the young's modulus of polystyrene foam is E=3000Mpa, Poisson's ratio of polystyrene foam is We select the section of the TV and cushion pad, in order to facilitate the calculation, increase the width of the pad to reduce the computational error. Using ABAQUS to establish the plane model, as shown in Figure The selection and division of the grid Fig. 1 Finite element model of TV slammed into the ground. According to the packaging safety requirements, we choose to make an explicit dynamic analysis of the cushion pad[13-14]. Relative to the implicit dynamic method[15], explicit dynamics has a faster solution, and has better convergence property. The grid unit uses the plane strain element CPE4R, which is a kind of hourglass function

4 Gui Kun and Wang Xi / Procedia Engineering 174 ( 2017 ) reduced integration unit. On the premise of explicit dynamic analysis, the calculation speed and accuracy can be improved effectively. Unit partition is shown in Figure 2. Fig. 2 Finite element model of meshing Conclusion analysis Through calculation, we know that when the TV hit the ground, the speed is v=0. 024m/s. After reaching the ground, due to the buffering effect of polystyrene foam, the TV will do deceleration motion, until the kinetic energy turn into elastic potential energy of liner. In order to get the approximate distance, we assume that the television is colliding with the ground at a speed of v=0. 024m/s and keep it moving, to obtain the relationship of elastic potential energy of liner and TV vertical displacement (product of time and speed),. After calculation, get the results as shown in Figure 3. Fig. 3 Elastic potential energy and time Figure 4 shows that when t= , the elastic potential energy is equal to the gravitational potential energy. The gravitational potential energy W can be calculated as follows:

5 908 Gui Kun and Wang Xi / Procedia Engineering 174 ( 2017 ) W mgh 20kg 9.8N / s 0.25m 49J (3) In the formula: W is the gravitational potential energy, m is the quality of the goods, g is gravity acceleration, H is the drop height. In order to ensure the security, the value is appropriate to take a large, and in the final calculation, the impact of the television is seen as a deceleration movement. So that the initial speed of the television is v=0. 024m/s, uniformly retarded motion speed becomes zero after s. The increase of the elastic potential energy is obtained as shown in Figure 4. Fig. 4 Elastic potential energy and time of final model From Figure 5, the model's final elastic potential energy is 58J, the fall situation can be better estimated. Through the ABAQUS simulation analysis, get the mises stress diagram while the television hits the ground, as shown in figure 5. You can calculate the maximum stress is 27Mpa<225Mpa, it is very safe. Fig. 5 The impact process stress diagram of mises

6 Gui Kun and Wang Xi / Procedia Engineering 174 ( 2017 ) Conclusion In this paper, through five steps of packaging design, the specific material of polystyrene foam was firstly determined and selected. Then the thickness of the pad is obtained by consulting and calculating, so as to design the packaging liner, and finally get the Mises stress by the simulation analysis of finite element software ABAQUS. And the performance of its resistance to impact is verified, proving that our package design meets the design requirements. References [1] Chen Peng. Marketing Study of Chongqing Corrgated Papper Box Market. Chongqing: Xinan University, [2] Frank B. Corrugated Box Compression-A Literature Survey. Packaging Technology and science, 2014, 27(2): [3] Zhang G Q, Du Y F, Li X Z, et al. Parametric Design and Multi-Objective Optimization of LCD Packaging Cushion Foams. Applied Mechanics & Materials, 2012, 200: [4] Xu Jie, Wang Yu-long, Lu Xiao-juan, etal. The Research of Cushioning Packing Design Method for Honeycomb Paperboard. Wuhan: The National Packaging Engineering Academic Conference, [5] Dai Hong-min, DAI Pei-hua. Six-step Design Method of Paper Pulp Modeling Cushion Packaging. Packaging Engineering, 2010, 31(19): [6] Wen Shi-bao, Chao Kai-hua, Wang Bin, etal. Corrugated Composite Paperboard and Its Mechanical Properties. Packaging and Food Machine, 2012, 30(3): [7] Wang J, Wang Z W, Gao D, etal. Dropping shock response of corrugated paperboard cushioning packaging system. Journal of Vibration & Control, 2013, 19(3): [8] Kim W J, Kum D H, Park S H. Effective Design of Cushioning Package to Improve Shockproof Characteristics of Large-Sized Home Appliances. Mechanics Based Design of Structures & Machines, 2009, 37(1):1-14. [9] Duan Ning-ning. The Dynamical Characteristics of Tilted Support Spring Packaging System with Critical Components. Wuxi:Jiangnan University. [10] Huang Zhi-gang, Zhu Hui, An Hui-min. The Development and Trend of Packaging Dynamic. Journal of BeiJing Institute of Light Industry, 2000, 18(3): [11] Zhao Yu-cong, Zhang Li-na, Liu Cheng. Analysis of Dynamic Fragility of LCD TV in Drop Test. Packaging Engineering, 2013, 34(9): [12] Du Cheng, Yang Jun. The characteristics and application of polystyrene foam (EPS) analysis. Journal of southeast university (natural science edition), 2001, 31(3): [13] Namadchi A H, Alamatian J. Explicit dynamic analysis using Dynamic Relaxation method. Computers & Structures, 2016(175): [14] Zhu Yue-feng. Research on Analysis Methods of Explicit Dynamics Based on ABAQUS. Machinery Design Manufacture, 2015(3): [15] Ma Huai-fa, Wang Li-tao, Liang Guo-ping. Implicit damping iterative algorithm for elastoplastic dynamical equations. Journal of hydroelectric power, 2011, 30(6):71-74.