Simulation based aerosol can design under pressure and buckling loads and comparison with experimental trials

The present paper focuses on the methodology to simulate an aerosol can when subject to internal pressure and top compressive loadings. Non-linear numerical analysis seeks to predict the level of pop-up and burst pressure levels as the can is subjected to increased pressure loading, along with the determination to top load force causing can wall buckling. These predictions are necessary to access the conformity of the can design to the European Packaging Standard. Numerical findings are assessed against experimental trials for reliability of such a simulation based approach for can design. The challenge of the present study is the use of in situ data to mimic the can predictive behaviour within the Ansys Software suite. This data includes the can material, which is non-linear strain hardening aluminium allowing for yielding at high strain, can wall variable thickness and loading characteristics. The paper highlights some of the modelling issues associated with such analyses and provides some guidance to improve the aerosol can design. The methodology will be used, in a following study, in reducing the can weight by optimal distribution of the can wall thickness whilst revealing an innovative design that fulfils the qualification needs. This will have a direct impact on the material cost, in addition to cost of transport and energy.