Search Results (16)

Cellular materials such as aluminum and polyurethane foams are recognized for their effectiveness in energy absorption. They commonly serve as crushable cores in sacrificial cladding for blast mitigation purposes. This study delves into the effectiveness of autoclaved aerated concrete (AAC), a lightweight, porous material known for its energy-absorbing properties as a crushable core in sacrificial cladding. The experimental set-up features a rigid frame made of steel measuring 1000 × 1000 × 15 mm³ with a central square opening (300 × 300 mm²) holding a 2 mm thick aluminum plate representing the structure. The dynamic response of the aluminum plate is captured using two high-speed cameras arranged in a stereoscopic configuration. Three-dimensional digital image correlation is used to compute the transient deformation fields. Blast loading is achieved by detonating 20 g of C4 explosive set at 250 mm from the plate’s center. The study assesses the mineral foam’s absorption capacity by comparing out-of-plane displacement and mean permanent deformation of the aluminum plate with and without the protective solution. Six foam configurations (A to F) are tested experimentally and numerically, varying in the foam’s free space for expansion relative to its total volume. Results show positive protective effects, with configuration F reducing maximum deflection by at least 30% and configuration C by up to 70%. Foam configuration influences energy dissipation, with an optimal lateral surface-to-volume ratio (ζ) enhancing protective effects, although excessive ζ leads to non-uniform foam crushing. To address the influence of front skin deformability, a non-deformable front skin has been adopted. The latter demonstrates an increased effectiveness of the sacrificial cladding, particularly for ζ values above the optimal value obtained when using a deformable front skin. Notably, using a non-deformable front skin increases maximum deflection reduction and foam energy absorption by up to approximately 30%. Full article

In this research, a new computational method was proposed for describing the mechanical behavior of super-elastic-plastic foams under inhomogeneous compressive impacts. The method regarded the foam material as composed of two typical mechanical properties superimposed multiple times: one was the hyper-elastic layer, and the other was the elastoplastic layer. The hyper-elastic layer and the elastoplastic layer were interwoven and overlapped, divided into double-layer, four-layer, and six-layer configurations to characterize the foam material. After the equivalent layering of the foam, by comparing the results of the four-layer and six-layer divisions, it was found that when the layering reached four layers, the foam performance curve had already converged. The study utilized the HYPERFOAM model and Mullins effect in the ABAQUS software to establish the constitutive relationship of the hyper-elastic layer. It adopted the Crushable foam model to develop the constitutive relationship of the elastoplastic layer. Under uniaxial compression conditions, quasi-static and intermediate strain rate compression tests were performed on polyethylene (PE) foam materials with three different densities. Based on the experimental results, the parameter values of the hyper-elastic-plastic foam model in the ABAQUS code were determined. By comparing the computational results and the experimental results, the established finite element (FE) model was validated using the mechanical behavior of indentation and compression tests. The results showed that this method could effectively describe the complex mechanical behavior and residual deformation of hyper-elastic-plastic foam packaging materials under non-uniform compression, and the experimental and simulation results agreed well, proving the reliability of this method. Full article

The plastic properties for the jellyroll of lithium-ion batteries showed different behavior in tension and compression, showing the yield strength in compression being several times higher than in tension. The crushable foam models were widely used to predict the mechanical responses to compressive loadings. However, since the compressive characteristic is dominant in this model, it is difficult to identify distributions of the yield strength in tension. In this study, a simplified jellyroll model consisting of double-layer windings was devised to reflect different plastic characteristics of a jellyroll, and the proposed model was applied to an 18650 cylindrical battery under compressive loading conditions. One winding adopted the crushable foam model for representing the compressive plastic behavior, and the other winding adopted the elastoplastic models for tracking the tensile plastic behavior. The material parameters in the crushable foam model were calibrated by comparing the simulated force–displacement curve with the experimental one for the case where the cell was crushed between two plates when the punch was displaced by 7 mm. A specific cut-off value (10 MPa) was assigned to a yield stress limit in the elastoplastic model. Further, the computational model was validated with two more loading cases, a cylindrical rod indentation and a spherical punch indentation, as the punch was displaced by 6.3 mm and 6.5 mm, respectively. For three loading cases, deformed configurations and plastic strain distributions were investigated by finite element analysis. It was found that the proposed model clearly provides the plastic behavior both in compression and tension. For the crush simulation, the maximum compressive stress approached 222 MPa in the middle of the jellyroll, and the maximum effective plastic strain approached 60% in the middle of the layered roll. For indentation with the cylindrical and the spherical punch, the maximum effective plastic strain approached 52% and 277% in the layered roll, respectively. The local crack or location of a short circuit could be predicted from the maximum effective plastic strain. Full article

Crushable foam plasticity models are employed to simulate material response under essentially monotonic loading. For the plastic part of the behavior, the default crushable foam model in Abaqus/Explicit is the volumetric hardening model, where the yield surface evolves by the volumetric compacting plastic strain, and the other available model is the isotropic hardening model, where the yield curve is centrally located at the origin in the pressure—the Mises stress plane. In this study, the characteristic of two models was examined by applying them to a simple 18650 lithium-ion cylindrical cell. The computation cell model consists of the shell casing and the homogenized jelly roll which represents the electrode assembly. Both crushable foam models were calibrated to represent the homogenized mechanical properties of the jellyroll, and the load–displacement relations were compared with the experimental results. Then, we examined the deformation characteristic of jellyroll for each crushable foam model. Full article

This study explores the application of numerical analysis and material models to predict ice impact loads on ships and offshore structures operating in polar regions. An explicit finite element analysis (FEA) approach was employed to simulate an ice and steel plate collision experiment conducted in a cold chamber. The pressure and strain history during the ice collision were calculated and compared with the experimental results. Various material model configurations were applied to the FEA to account for the versatile behavior of ice (whether ductile or brittle), its elastic-plastic yield criteria, and its dynamic strain rate dependency. In addition to the standard linear elastic-perfectly plastic and linear elastic-plastic relationships, this study incorporated the Crushable Foam and Drucker–Prager models, based on the specific ice yield criteria. Considering the ice’s strain rate dependency, collision simulations were conducted for each yield criteria model to compute the strain and reaction force of the plate specimens. By comparing the predicted pressures for each material model combination with the pressures from ice collision experiments, our study proposes material models that consider the yielding, damage, and behavioral characteristics of ice. Lastly, our study proposes a combination of ice material properties that can accurately predict collision force. Full article

The evaluation of structural crashworthiness is important for the development of civil aircraft. In this study, cargo luggage was considered in the vertical drop simulation of an aircraft mid-fuselage section. First, quasi-static compression tests on three types of luggage made of different materials were conducted. Then, a finite element model (FEM) of the cargo luggage was developed with a crushable foam material in LS-PrePost4.5 software. The finite element analysis results of the luggage made of different materials were consistent with the corresponding compression experiments. Secondly, the FEM of the mid-fuselage section was established without cargo luggage. The simulated displacement and acceleration of the fuselage section were consistent with the test results. Finally, the influences of cargo luggage on the fuselage vertical drop response were studied with the FEM considering both the fuselage structure and cargo luggage. Compared with the responses of the fuselage without cargo luggage, the cargo luggage could reduce the deformation of the cargo bay and maintain the integrity of the passenger living space in the cabin at the vertical velocity of 6 m/s, even though the initial kinetic energy was higher. Full article

Additively manufactured synthetic bone scaffolds have emerged as promising candidates for the replacement and regeneration of damaged and diseased bones. By employing optimal pore architecture, including pore morphology, sizes, and porosities, 3D-printed scaffolds can closely mimic the mechanical properties of natural bone and withstand external loads. This study aims to investigate the deformation pattern exhibited by polymeric bone scaffolds fabricated using the PolyJet (PJ) 3D printing technique. Cubic and hexagonal closed-packed uniform scaffolds with porosities of 30%, 50%, and 70% are utilized in finite element (FE) models. The crushable foam plasticity model is employed to analyze the scaffolds’ mechanical response under quasi-static compression. Experimental validation of the FE results demonstrates a favorable agreement, with an average percentage error of 12.27% ± 7.1%. Moreover, the yield strength and elastic modulus of the scaffolds are evaluated and compared, revealing notable differences between cubic and hexagonal closed-packed designs. The 30%, 50%, and 70% porous cubic pore-shaped bone scaffolds exhibit significantly higher yield strengths of 46.89%, 58.29%, and 66.09%, respectively, compared to the hexagonal closed-packed bone scaffolds at percentage strains of 5%, 6%, and 7%. Similarly, the elastic modulus of the 30%, 50%, and 70% porous cubic pore-shaped bone scaffolds is 42.68%, 59.70%, and 58.18% higher, respectively, than the hexagonal closed-packed bone scaffolds at the same percentage strain levels. Furthermore, it is observed in comparison with our previous study the μSLA-printed bone scaffolds demonstrate 1.5 times higher elastic moduli and yield strengths compared to the PJ-printed bone scaffolds. Full article

Orthopaedic surgical cutting instruments are required to generate sufficient forces to penetrate bone tissue while minimising the risk of thermal and mechanical damage to the surrounding environment. This study presents a combined experimental–computational approach to determine relationships between key cutting parameters and overall cutting performance of a polyurethane-based synthetic trabecular bone analogue under orthogonal cutting conditions. An experimental model of orthogonal cutting was developed, whereby an adaptable cutting tool fixture driven by a servo-hydraulic uniaxial test machine was used to carry out cutting tests on Sawbone^® trabecular bone analogues. A computational model of the orthogonal cutting process was developed using Abaqus/Explicit, whereby an Isotropic Hardening Crushable Foam elastic-plastic model was used to capture the complex post-yield behaviour of the synthetic trabecular bone. It was found that lower tool rake angles resulted in the formation of larger discontinuous chips and higher cutting forces, while higher rake angles tended to lead to more continuous chip formation and lower cutting forces. The computational modelling framework provided captured features of both chip formation and axial cutting forces over a wide range of cutting parameters when compared with experimental observations. This experimentally based computational modelling framework for orthogonal cutting of trabecular bone analogues has the potential to be applied to more complex three-dimensional cutting processes in the future. Full article

In the following work, sacrificial claddings filled with different brittle materials were investigated, from concrete foam to granular media. They were subjected to blast loading using an explosive driven shock tube, while a sensor measures the load transmission and a high speed camera records the compression of the core. From a macroscopic point of view, concrete foam and granular media can act efficiently as a crushable core but differs greatly in terms of energy dissipation mechanisms. To compare them, granular media was at first treated as a cellular material, and different key parameters (plateau stress, densification strain) were computed using the energy absorption efficiency methodology. The presented tests results, coupled with observation in literature, allow a better understanding on the crushing process of a granular media. In particular, granular media tend to work as a core even for low intensity load, contrary to more classical crushable core. Full article

Customizing any trauma surgery requires prior planning by surgeons. Nowadays, the use of numerical tools is increasingly needed to facilitate this planning. The success of this analysis begins with the definition of all the mechanical constitutive models of the materials implied. Our target is the trabecular bone because almost all trauma surgeries are closely related to it. This work focuses on the experimental characterization of porcine trabecular tibiae and defining its best constitutive model. Therefore, different types of compression tests were performed with tibia samples. Once the potential constitutive models were defined, stress–strain state from numerical approaches were compared with the corresponding experimental results. Experimental results from uniaxial compression tests showed than trabecular bone exhibits clear anisotropy with more stiffness and strength when it is loaded in the tibia longitudinal direction. Results from confined compression tests confirmed that the plastic behavior of trabecular bone depends on the hydrostatic and deviatoric invariants, so an alternative formulation (crushable foam volumetric (CFV)) has been proposed to describe its behavior. A new method to obtain CFV characteristic parameters has been developed and validated. Predictions of the CFV model better describe trabecular bone mechanical behavior under confined conditions. In other cases, classical plasticity formulations work better. Full article

Hybrid structures have the advantage of combining different types of materials at the same time. The trend of lightweight design in the transportation industry has promoted the development and application of composite materials with good crashworthiness performance. Low-density crushable foam-filled metal-composite hybrid structures have potential advantages as energy-absorbing components. This study investigated the mechanical characteristics of four different polyurethane foam-filled hybrid structures and their individual components under quasi-static axial compression. The experimental results showed foam-filled hybrid structures could change the deformation mode and improve stability during the compression process. Meanwhile, these hybrid structures could also improve energy absorption compared with their individual components. Among the different configurations, specimen C-PU-C (i.e., polyurethane foam filler between an outer CFRP tube and an inner CFRP tube) had the highest energy absorption capacity, at 5.4 kJ, and specific energy absorption, at 37.3 kJ/kg. Finally, a finite element (FE) model was established to analyze the mechanical characteristics of the hybrid structures by validating the simulation results against the experimental results. Full article

Closed-cell expanded polypropylene (EPP) foam is commonly used in car bumpers for the purpose of absorbing energy impacts. Characterization of the foam’s mechanical properties at varying strain rates is essential for selecting the proper material used as a protective structure in dynamic loading application. The aim of the study was to investigate the influence of loading strain rate, material density, and microstructure on compressive strength and energy absorption capacity for closed-cell polymeric foams. We performed quasi-static compressive strength tests with strain rates in the range of 0.2 to 25 mm/s, using a hydraulically controlled material testing system (MTS) for different foam densities in the range 20 g/dm³ to 220 g/dm³. The above tests were carried out as numerical simulation using ABAQUS software. The verification of the properties was carried out on the basis of experimental tests and simulations performed using the finite element method. The method of modelling the structure of the tested sample has an impact on the stress values. Experimental tests were performed for various loads and at various initial temperatures of the tested sample. We found that increasing both the strain rate of loading and foam density raised the compressive strength and energy absorption capacity. Increasing the ambient and tested sample temperature caused a decrease in compressive strength and energy absorption capacity. For the same foam density, differences in foam microstructures were causing differences in strength and energy absorption capacity when testing at the same loading strain rate. To sum up, tuning the microstructure of foams could be used to acquire desired global materials properties. Precise material description extends the possibility of using EPP foams in various applications. Full article

Sandwich panels have proven to be excellent energy absorbents. Such panels may be used as a protective structure in, for example, façades subjected to explosions. In this study, the dynamic response of sandwich structures subjected to blast loading has been investigated both experimentally and numerically, utilizing a shock tube facility. Sandwich panels made of aluminium skins and a core of extruded polystyrene (XPS) with different densities were subjected to various blast load intensities. Low-velocity impact tests on XPS samples were also conducted for validation and calibration of a viscoplastic extension of the Deshpande-Fleck crushable foam model. The experimental results revealed a significant increase in blast load mitigation for sandwich panels compared to skins without a foam core, and that the back-skin deformation and the core compression correlated with the foam density. Numerical models of the shock tube tests were created using LS-DYNA, incorporating the new viscoplastic formulation of the foam material. The numerical models were able to capture the trends observed in the experimental tests, and good quantitative agreement between the experimental and predicted responses was in general obtained. One aim of this study is to provide high-precision experimental data, combined with a validated numerical modelling strategy, that can be used in simulation-based optimisation of sandwich panels exposed to blast loading. Full article

The dynamic behavior of the lithium-ion battery is evaluated by simulating the full battery system and each corresponding component, including the jellyroll and thin-foil electrodes. The thin-foil electrodes were evaluated using a novel design of split Hopkinson tensile bar (SHTB), while the jellyroll was evaluated using the split Hopkinson pressure bar (SHPB). A new stacking method was employed to strengthen the stress wave signal of the thin-foil electrodes in the SHTB simulation. The characteristic of the stress–strain curve should remain the same regardless of the amount of stacking. The jellyroll dynamic properties were characterized by using the SHPB method. The jellyroll was modeled with Fu-Chang foam and modified crushable foam and compared with experimental results at the loading speeds of 20 and 30 m/s. The dynamic behavior compared very well when it was modeled with Fu-Chang foam. These studies show that the dynamic characterization of Li-ion battery components can be evaluated using tensile loading of stacked layers of thin foil aluminum and copper with SHTB methodology as well as the compressive loading of jellyroll using SHPB methodology. Finally, the dynamic performance of the full system battery can be simulated by using the dynamic properties of each component, which were evaluated using the SHTB and SHPB methodologies. Full article

Closed-cell aluminium foams were fabricated and characterised at different strain rates. Quasi-static and high strain rate experimental compression testing was performed using a universal servo-hydraulic testing machine and powder gun. The experimental results show a large influence of strain rate hardening on mechanical properties, which contributes to significant quasi-linear enhancement of energy absorption capabilities at high strain rates. The results of experimental testing were further used for the determination of critical deformation velocities and validation of the proposed computational model. A simple computational model with homogenised crushable foam material model shows good correlation between the experimental and computational results at analysed strain rates. The computational model offers efficient (simple, fast and accurate) analysis of high strain rate deformation behaviour of a closed-cell aluminium foam at different loading velocities. Full article