Development of model to simulate embossing of tissue paper: Effect of embossing on mechanical performance of tissue

Abstract: Tissue paper is a type of soft, absorbent, and lightweight paper with several applications for hygiene and kitchen use. Embossing is an operation during the converting stage of the tissue production process which creates relief designs on tissue. Other than producing designs for aesthetic purposes, embossing increases bulk which improves absorbency and softness but reduces mechanical strength and stiffness. A computational model using the finite element method is developed to simulate the embossing of tissue paper. A tool for fitting an appropriate material model for tissue to its experimental test data is implemented. The material model is subjected to a verification test and it works sufficiently well to model the in-plane elastic and plastic anisotropic behavior of tissue. Two validation tests are conducted to check the embossing model against experimental test data where it is observed that the model works well. Firstly, it provides an idea about the amount of pressure required to be applied during loading to reach a certain embossing level. Secondly, it predicts the tensile strength of embossed tissue sheets although it provides a slight underestimate. Potential reasons for the shortcomings in the tensile strength are suggested and recommendations for further improving the model are provided. Lastly, parametric studies are conducted to investigate the influence of embossing pattern geometry on the mechanical performance of embossed tissue.  After passing the verification and validation stages, the model is ready to serve as a convenient, less time-consuming, and cost-effective alternative to experimental testing to study the embossing process. It can also be used as a tool to examine the effect of one or more model parameters on embossing by simply changing them and studying the new results.