Finite Element/Fracture Mechanics Simulation of Trajectories
During Transverse Fracturing of Plastic Films

Transverse fracturing during processing of plastic sheet products is a common practice in industry, but the mechanics is not well understood at a detailed level. The purpose of our research is to develop finite element based simulation tools that will allow us to study the fracture trajectories. We are combining the fracture simulation capabilities of the Cornell Fracture Group software (initially, FRANC2D, but eventually, FRANC3D as well) with the analysis capabilities of ABAQUS to perform crack growth simulations in a multi-layered plastic sheet material that includes both material and geometric non-linearities.

The following sketch shows a typical example of a plastic sheet that is being cut (transversely fractured).

The fractures can start from both the upper and lower surface, thus, we must be able to capture the propagation and merging of seperate -- arbitrarily complex geometric features -- cracks. At the same time, we want to quantify the effects of the cutting force, the knife radius, and material properties on the predicted fracture trajectories.

The goal is to produce a single clean transverse fracture...

UPDATE: Progress Report presented to the Eastman-Kodak Co. on July 16, 2001