The Calculus of folding to make boxes

In summary, solving the problem in general terms yields that the width of the removed rectangles is equal to the length of the original rectangle minus the square of the length of the original rectangle.
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MarkFL
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A problem that students in their first semester of elementary calculus commonly encounter involves taking a rectangular sheet of some material, and cutting squares from each corner so that when the resulting two pairs of flaps are folded up, an open box results. The students are asked to find the dimensions of the squares removed that will maximize the volume of the resulting box.

I thought it might be instructive to work the problem in general terms. Please refer to the following diagram:

boxfold.jpg


The width of the original sheet of material is labeled $W$ and the length if labeled $L$. The squares cut from the corners are shaded in black, and are $x$ units in length on a side.

As we can see, when the resulting flaps are folded up, the base of the box has area $A=(W-2x)(L-2x)$ and the height of the box is $x$, and so the volume of the box, as a function of $x$ is:

\(\displaystyle V(x)=x(W-2x)(L-2x)=4x^3-2(L+W)x^2+LWx\)

Differentiating with respect to $x$ and equating the result to zero, we find:

\(\displaystyle V'(x)=12x^2-4(L+W)x+LW=0\)

Now, if we observe that the derivative is parabolic, and opening upwards, then the smaller of the two roots must be at a local maximum, since the derivative will be positive to the left of this root and negative to the right. Hence, the smaller of the two roots, by the quadratic formula, is:

\(\displaystyle x=\frac{L+W-\sqrt{L^2-LW+W^2}}{6}\)

Another problem of this type involves taking a rectangular sheet and removing congruent rectangles from two adjacent corners, leaving a shape that can be folded into a closed box.

Please refer to the following diagram:

boxfold2.jpg


The removed rectangles are shaded in black, the base and top of the resulting box shaded in red, and the two pairs of opposing sides are shaded in green and in blue.

The area of the base is:

\(\displaystyle b=\frac{1}{2}(W-2x)(L-2x)\)

And since the height of the box is $x$, we find the volume of the box can be given by:

\(\displaystyle V(x)=bx=\frac{1}{2}(W-2x)(L-2x)x\)

If we recognize that this volume function is simply a constant times the volume function from the previous problem, then we know we will find the same critical value:

\(\displaystyle x=\frac{L+W-\sqrt{L^2-LW+W^2}}{6}\)

And so the width of the removed rectangles is:

\(\displaystyle w=\frac{W}{2}+x=\frac{L+4W-\sqrt{L^2-LW+W^2}}{6}\)
 

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Thanks @MarkFL! What math forum can we move this to?
 

FAQ: The Calculus of folding to make boxes

1. What is the "Calculus of folding to make boxes"?

The Calculus of folding to make boxes is a mathematical concept that deals with finding the optimal way to fold a flat sheet of material in order to create a box with the desired dimensions.

2. How is the "Calculus of folding to make boxes" used in real life?

The Calculus of folding to make boxes is used in various industries, such as packaging and manufacturing, to optimize the use of materials and create efficient and cost-effective packaging solutions.

3. What are some of the key principles of the "Calculus of folding to make boxes"?

Some key principles of the Calculus of folding to make boxes include minimizing the amount of material used, maximizing the volume of the box, and maintaining structural integrity.

4. How does the "Calculus of folding to make boxes" differ from traditional calculus?

The Calculus of folding to make boxes differs from traditional calculus in that it specifically focuses on the geometric properties of folding and maximizing volume, rather than general mathematical functions and equations.

5. What are some challenges that arise when using the "Calculus of folding to make boxes"?

Some challenges that may arise when using the Calculus of folding to make boxes include determining the optimal number and location of folds, accounting for material thickness and stiffness, and considering the effects of creases and seams on the final box dimensions.

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