Impact modeling of foam cored sandwich plates with ductile or brittle faceplates

This paper reports numerical results of low velocity impact on open-face sandwich plates with an impactor of 2.65 kg mass hitting with 6.7 m/s velocity. The numerical simulation is done using 3D finite element models in LS-DYNA. The sandwich plates used for the present work have a core made of commercial aluminum alloy foam (Alporas) with faceplates made of either ductile aluminum (Al) or brittle carbon fiber reinforced plastic (CFRP). Selection of suitable constitutive models and erosion criterion for the failure analysis is investigated. A simplified analytical model for the peak load prediction under punch-through failure mode is presented. Numerically predicted contact force versus time, energy absorbed versus time along with the failure modes are compared with the experimental measurements and observations. Within experimental scatter, there is a good agreement between the numerical predictions and experimental measurements. Further more, the analytically predicted peak load values are in excellent agreement with the experimental measurements.     

Lightweight design and crash analysis of composite frontal impact energy absorbing structures

Carbon fibre composites have shown to be able to perform extremely well in the case of a crash and are being used to manufacture dedicated energy-absorbing components, both in the motor sport world and in constructions of aerospace engineering. While in metallic structures the energy absorption is achieved by plastic deformation, in composite ones it relies on the material diffuse fracture. The design of composite parts should provide stable, regular and controlled dissipation of kinetic energy in order to keep the deceleration level as least as possible. That is possible only after detailed analytical, experimental and numerical analysis of the structural crashworthiness.This paper is presenting the steps to follow in order to design specific lightweight impact attenuators. Only after having characterised the composite material to use, it is possible to model and realise simple CFRP tubular structures through mathematical formulation and explicit FE code LS-DYNA. Also, experimental dynamic tests are performed by use of a drop weight test machine.Achieving a good agreement of the results in previously mentioned analyses, follows to the design of impact attenuator with a more complex geometry, as a composite nose cone of the Formula SAE racing car. In particular, the quasi-static test is performed and reported together with numerical simulation of dynamic stroke. In order to initialize the collapse in a stable way, the design of the composite impact attenuator has been completed with a trigger which is consisted of a very simple smoothing (progressive reduction) of the wall thickness. Initial requirements were set in accordance with the 2008 Formula SAE rules and they were satisfied with the final configuration both in experimental and numerical crash analysis.     

Computational and experimental crash analysis of the road safety barrier

The paper describes the computational analysis and experimental crash tests of a new road safety barrier. The purpose of this research was to develop and evaluate a full-scale computational model of the road safety barrier for use in crash simulations and to further compare the computational results with real crash test data. The impact severity and stiffness of the new design have been evaluated with the dynamic nonlinear elasto-plastic analysis of the three-dimensional road safety barrier within the framework of the finite element method with LS-DYNA code. Comparison of computational and experimental results proved the correctness of the computational model. The tests have also shown that the new safety barrier assures controllable crash energy absorption which in turn increases the safety of vehicle occupants.     

泡沫铝填充薄壁铝合金多胞构件与单胞构件吸能性能研究

为研究泡沫铝填充薄壁铝合金多胞结构与单胞结构的吸能能力,该文基于有限元软件LS-DYNA建立了泡沫铝填充薄壁铝合金多胞结构与单胞结构的数值仿真。对经典薄壁圆管试验及泡沫铝填充薄壁圆管试验进行了数值模拟,分析表明该数值模型能够较好的模拟泡沫铝填充薄壁圆管在轴向冲击过程中的撞击力和变形发展。基于该模型对比研究了不同因素下泡沫铝填充薄壁铝合金多胞结构与单胞结构的轴向吸能特性,分析了其破坏模式、吸能机理和两者吸能效率。结果表明:在轴向冲击荷载作用下,泡沫铝填充薄壁铝合金的破坏模式为轴对称渐进折叠破坏模式,冲击力-位移曲线和变形模态图显示其变形过程分为3个阶段:弹性阶段、平台阶段和强化阶段。当冲击压缩距离为构件高度的80%时,7种不同参数下的泡沫铝填充薄壁铝合金多胞结构的吸能效率明显高于7种单胞结构,吸收的能量E和比吸能SEA都提高了50%以上,是一种优秀的吸能构件,可广泛应用于防护工程中。     

Crushing energy absorption of GFRP sandwich panels and corresponding monolithic laminates

Steady quasi-static compression of GFRP monolithic laminates and sandwich panels made of a randomly oriented continuous filament mat/polyester were undertaken. The effects of facing/laminate thickness, trigger collapse system and aspect ratio on their failure mechanisms, hence their energy absorption capability were examined. A numerical model, using a non-linear finite element explicit code, LS-DYNA, was used for pre-analysis of the effect of aspect ratio. A collapse trigger configuration was also studied numerically. The experimental data showed that high values of energy absorbed per unit mass were a predominant feature of the thickest monolithic laminates and sandwich panels with the thickest facings. The monolithic laminates showed higher specific energy than their sandwich panel counterparts. It seems that this difference was due to instability of the sandwich specimens.     

Design of an aluminium-based vehicle platform for front impact safety

The current paper examines the design of an aluminium-intensive small car platform for desirable front impact safety performance. A space frame-type architecture comprised of extruded aluminium members with welded joints is considered for inherent structural rigidity, and low investment in terms of tooling. A finite element model of the vehicle is employed for crash analysis using the explicit code LS-DYNA. Confidence in analysis is established at the component level by benchmarking finite element models of welded joints against experimental data, and axial crushing of aluminium tubes against published numerical results and theoretical prediction. A numerical design of experiments is conducted for arriving at a front-end design that will yield desirable safety performance during impact against a rigid barrier at 30 mph (FMVSS 208 condition). For comparable new car assessment program performance at a higher speed of 35 mph, a lumped parameter idealization is used to identify the principal design changes that may be necessary. The current approach of component level testing combined with finite element and lumped parameter-based simulations can be regarded as an effective and time-saving procedure in the crash safety design of new vehicles.     

Effects of Stacking Sequence and Impactor Diameter on Impact Damage of Glass Fiber Reinforced Aluminum Alloy Laminate

The methods of numerical simulation and test are combined to analyze the impact behavior of glass fiber reinforced aluminum alloy laminate (GLARE). A new failure criteria is proposed to obtain the impact failure of GLARE, and combined with material progressive damage method by writing code of LS-DYNA. Low velocity impact test of GLARE is employed to validate the feasibility of the finite element model established. The simulation results have been shown that progressive damage finite element model established is reliable. Through the application of the finite element model established, the delamination of GLARE evolution progress is simulated, various failure modes of GLARE during impact are obtained, and the effects of stacking sequence and impactor diameter on the impact damage of GLARE are obtained.     

风致飞掷物冲击建筑浮法玻璃试验和数值模拟

通过试验和有限元数值模拟的方法研究风致飞掷物对建筑浮法玻璃的冲击破坏效应。首先进行钢球冲击浮法玻璃面板的破坏试验,然后基于LS-DYNA建立与试验对应的飞掷物冲击浮法玻璃有限元模型,并通过对比试验和数值模拟的结果验证有限元模型的可靠性。最后基于验证后的有限元模型,以板状飞掷物为代表,研究风致飞掷物的冲击位置、冲击姿态和外形等特性对其冲击效应的影响。结果表明,建筑浮法玻璃在风灾中非常容易受到飞掷物的冲击而破坏。采用JH-2作为浮法玻璃的本构模型并以SIGP1=75 MPa作为失效准则,能够较准确地模拟浮法玻璃在冲击荷载下的破坏特性。板状飞掷物的冲击位置对其冲击效应影响不大,但其冲击姿态和边厚比对冲击效应有较大的影响。     

Numerical modelling of the boundary conditions on beams stuck transversely by a mass

In this paper, numerical results of a drop weight impact test examining the dynamic response of a clamped steel beams struck transversely at the centre by a mass with a rectangular indenter are presented. The numerical simulation showed that the results are very sensitive to the way in which the supports are modelled and thus this paper studies the modelling of the structural supports used to clamp the specimen beam in the experiment. The first approach simplifies the structural support as boundary condition on the nodes; the second model represents the entire support as the real approximation; the last approach uses simplified support plate model acting with the beam to simulate the experimental set up. The complete force-displacement curve is used to compare the plastic deformation of the impacted beams, thus the best approximation is selected for further calculations. The finite element model was performed using the LS-DYNA non-linear, dynamic finite element software. The numerical calculations can predict accurately the response of deflections, forces and absorbed energies, when proper boundary conditions are applied, in this case with shell elements representing the support plates.     

Predicting low-velocity impact damage on a stiffened composite panel

An intralaminar damage model, based on a continuum damage mechanics approach, is presented to model the damage mechanisms occurring in carbon fibre composite structures incorporating fibre tensile and compressive breakage, matrix tensile and compressive fracture, and shear failure. The damage model, together with interface elements for capturing interlaminar failure, is implemented in a finite element package and used in a detailed finite element model to simulate the response of a stiffened composite panel to low-velocity impact. Contact algorithms and friction between delaminated plies were included, to better simulate the impact event. Analyses were executed on a high performance computer (HPC) cluster to reduce the actual time required for this detailed numerical analysis. Numerical results relating to the various observed interlaminar damage mechanisms, delamination initiation and propagation, as well as the model’s ability to capture post-impact permanent indentation in the panel are discussed. Very good agreement was achieved with experimentally obtained data of energy absorbed and impactor force versus time. The extent of damage predicted around the impact site also corresponded well with the damage detected by non destructive evaluation of the tested panel.     

Simulation of progressive damage development in braided composite tubes under axial compression

A continuum damage mechanics based model for composite materials (CODAM), which has been implemented as a user material model in an explicit finite element code (LS-DYNA), is used to capture the complete tensile and compressive response of a braided composite material. Model parameters are related to experimentally observed behaviour to ensure a physical basis to the model and a crack band scaling approach is used to minimize mesh sensitivity (or lack of objectivity) of the numerical results. The predictive capability of the model is validated against the results from dynamic tube crush experiments. The damage propagation, failure morphology and energy absorption predictions correlate well with the experimental results.     

Numerical Study on Hybrid Tubes Subjected to Static and Dynamic Loading

The commercial finite element program LS-DYNA was employed to evaluate the response and energy absorbing capacity of cylindrical metal tubes that are externally wrapped with composite. The numerical simulation elucidated the crushing behaviors of these tubes under both quasi-static compression and axial dynamic impact loading. The effects of composite wall thickness, loading conditions and fiber ply orientation were examined. The stress–strain curves under different strain rates were used to determine the dynamic impact of strain rate effects on the metal. The results were compared with those of a simplified analytical model and the mean crushing force thus predicted agreed closely with the numerical simulations. The numerical results demonstrate that a wrapped composite can be utilized effectively to enhance the crushing characteristics and energy absorbing capacity of the tubes. Increasing the thickness of the composite increases the mean force and the specific energy absorption under both static and dynamic crushing. The ply pattern affects the energy absorption capacity and the failure mode of the metal tube and the composite material property is also significant in determining energy absorption efficiency.     

Experimental and numerical investigations of the impact behaviour of composite frontal crash structures

The present paper deals with the lightweight design and the crashworthiness analysis of a composite impact attenuator for a Formula SAE racing car, in order to pass homologation requirements. The analysed impact attenuator is manufactured by lamination of prepreg sheets in carbon fibres and epoxy matrix, particularly used for sporting applications, and has a very similar geometry to a square frusta, so as to obtain a progressive and controlled deformation. During the design, attention was focused on the material distribution and gradual smoothing, but also on the lamination process, which can heavily affect the energy absorption capability. To reduce the development and testing costs of a new safety design, computational crash simulations for early evaluation of safety behaviour under vehicle impact test were carried out. The dynamic analysis was therefore conducted both numerically, using an explicit finite element code such as LS-DYNA, and experimentally, by means of an appropriately instrumented drop weight test machine, in order to validate the model in terms of deceleration values during crushing. To assess the quality of the simulation results, a comparative analysis was initially developed on simple CFRP composite tubes subjected to dynamic axial loading. The numerical analysis was conducted using both shell and solid elements, in order to reproduce not only the brittleness of the composite structure but also the effective delamination phenomenon. Both the analyses show a good capacity to reproduce the crushing process; this is confirmed by the fact that model estimated displacements and accelerations are in close agreement with observed values for these variables. This confirms the quality of the methodology and approach used for the design of a racing car impact attenuator.     

Finite element analysis for the evaluation of the low-velocity impact response of a composite plate

The low-velocity impact responses of cross-ply CFRP composite plates are investigated experimentally and are simulated using the finite element code LS-DYNA. An experimental test was initially performed and two different modeling approaches were then employed to model the composite plates. In the first numerical modeling approach, solid elements are utilized for the composite layers, whereas in the second, shell elements are used. The numerical model using the shell elements shows a good correlation with the experimental results, while the impact damage in the form of delamination is predicted more precisely using solid elements.     

纤维金属层板低速冲击试验和数值仿真

为开展纤维金属层板（FML）低速冲击有限元数值仿真研究,改进了传统的连续损伤力学（CDM）模型,然后对FML落锤低速冲击试验进行数值仿真,并与实验结果进行对比验证。分别采用5.11 J 和10.33 J冲击能量对FML进行落锤低速冲击试验,得到冲击载荷、位移和能量时程曲线,分析FML的动态响应和失效模式。建立了考虑塑性应变、压缩刚度衰减特征和纤维拉伸断裂损伤的新CDM模型,描述S2-玻璃纤维/环氧树脂（S2-galss/epoxy）复合材料的损伤本构,并编写VUMAT子程序,通过ABAQUS/Explicit求解器对FML落锤冲击试验进行数值仿真。研究结果表明：低能量冲击条件下,FML背面主要为鼓包和裂纹等失效模式,位移峰值随冲击能量的提高而增加,冲击载荷峰值在穿透前也随冲击能量的提高而增加;采用改进的CDM模型描述FML中S2-galss/epoxy复合材料铺层后,有限元数值计算可以较好地预测FML低速冲击载荷下的动态响应;有限元数值仿真结果表明,FML中第2层复合材料铺层发生的纤维断裂损伤比第1层的更严重。     

An approach to combining 3D discrete and finite element methods based on penalty function method

An algorithm combining three-dimensional (3D) discrete and finite element methods is proposed. This new approach is conducted by decomposing the calculation domain into a finite element (FE) calculation domain and a discrete element (DE) calculation domain; the interaction between the two sub-domains is processed by using a penalty function method. Following the established model that combines spherical DEs and FEs, the corresponding numerical code is developed. The vibration process of two cantilever beams under dynamic force is simulated. By comparing the results calculated with different penalty factors set and also with that calculated by the finite element code LS-DYNA, it is found that the calculated results are unanimous and the precision is almost the same as LS-DYNA, as long as the penalty factor is large enough. Moreover, the vibration processes of two plates under impact of rigid spheres are simulated and the accuracy of the model proposed in this paper is further proved in the field of contact mechanics by comparing the simulating results with that calculated by using LS-DYNA. Finally, the impact fracture behavior of a laminated glass plate is simulated, with the influence of model parameters taken into consideration. And the numerical experiments show that the combined model can be used to predict some macroscopical physical quantities, such as the impact force of impactor.     

Numerical simulation of impact tests on GFRP composite laminates

The design of advanced composite structures or components subjected to dynamic loadings requires a deep understanding of the damage and degradation mechanisms occurring within the composite material. The present paper deals with the numerical simulation of low-velocity impact tests on glass fabric/epoxy laminates through the LS-DYNA Finite Element (FE) code. Two laminates of different thickness were subjected to transverse impact at different energy levels and modeled by FE. Solid finite elements combined with orthotropic failure criteria were used to model the composite failure and stress based contact failure between plies were adopted to model the delamination mechanism. The final simulation results showed a good correlation with experimental data in terms of both force–displacement curves and material damage.     

碳纤维层合板弹体冲击仿真方法研究

为了研究碳纤维增强复合材料层合机匣对高速撞击碎片的包容能力,通过LS-DYNA对圆柱弹体撞击BMS8-212层合增强复合材料进行动态仿真计算。有限单元计算模型中,层板材料采用连续损伤材料本构模型,层间采用固连失效接触模式。通过与试验结果的比较,验证了数值仿真方法的可靠性。发现,纤维增强复合材料层合板在弹体的横向高速撞击下主要的失效形式为纤维剪切、纤维和基体挤压、分层破坏、拉伸失效。     

铝塑复合包装材料废弃物分选技术

目的 针对铝塑复合包装材料废弃物分离不够彻底,导致产品纯度不高、分离效率低、分离工艺不够完善等问题,采用绿色环保的铝塑活性介质进行铝塑分选技术研究,优化分离工艺参数.方法 选择天然固体酸柠檬酸溶液作为铝塑复合废料分选的分离溶剂,研究柠檬酸浓度、反应温度、液固比、搅拌速度和裁切尺寸等因素对铝塑复合材料分离效果的影响.并根据正交试验和极差分析优化出分离时间短、铝损失率较低的分离工艺.结果 在柠檬酸浓度为2 mol/L,温度为100℃,液固比为400 L/kg,搅拌速度为650 r/min,裁切尺寸为0.5 cm×0.5 cm的条件下,铝塑分离率达到100％,分离时间为65 min,铝的质量损失率为0.66％.结论 柠檬酸作为一种新型天然分离剂,对铝的腐蚀率低,此技术为铝塑复合材料废弃物回收再利用工业化生产提供了参考.