Effect of aluminum closed-cell foam filling on the quasi-static axial crush performance of glass fiber reinforced polyester composite and aluminum/composite hybrid tubes

The effect of Al closed-cell foam filling on the quasi-static crushing behavior of an E-glass woven fabric polyester composite tube and thin-walled Al/polyester composite hybrid tube was experimentally investigated. For comparison, empty Al, empty composite and empty hybrid tubes were also tested. Empty composite and empty hybrid tubes crushed predominantly in progressive crushing mode, without applying any triggering mechanism. Foam filling was found to be ineffective in increasing the crushing loads of the composite tubes over the sum of the crushing loads of empty composite tube and foam. However, foam filling stabilized the composite progressive crushing mode. In empty hybrid tubes, the deformation mode of the inner Al tube was found to be a more complex form of the diamond mode of deformation of empty Al tube, leading to higher crushing load values than the sum of the crushing load values of empty composite tube and empty metal tube. The foam filling of hybrid tubes however resulted in axial splitting of the outer composite tube due to the resistance imposed by the foam filler to Al tube inward folding and hence it was ineffective in increasing crushing load and SAE values over those of empty hybrid tubes.     

Effect of anisotropy,kinematic hardening,and strain-rate sensitivity on the predicted axial crush response of hydroformed aluminium alloy tubes

There exists considerable motivation to reduce vehicle weight through the adoption of lightweight materials while maintaining energy absorption and component integrity under crash conditions. Aluminium and magnesium alloys, advanced high-strength steels, and composites are all proposed candidates for replacing mild steel in automotive structures. It was of particular interest to study the crash behaviour of lightweight tubular hydroformed structures. Thus, the current research has studied the dynamic crush response of hydroformed Al–Mg–Mn aluminium alloy tubes using both experimental and numerical methods. The research focused on axial crush structures that are designed to absorb crash energy by progressive axial folding. The main experimental parameter that was varied during the hydroforming process was the corner-fill radius of the tube. Numerical studies were carried out using explicit dynamic finite element models incorporating advanced constitutive material models to capture the measured forming and crash history. A constitutive model was implemented in the finite element models combining the Johnson–Cook strain-rate sensitivity model, a non-linear isotropic-kinematic hardening model, and the Yld2000-2d anisotropic model. Each effect was isolated, and it was shown that strain-rate sensitivity slightly increased the energy absorption capabilities while kinematic hardening and anisotropy effects decreased the energy absorption capabilities during axial crush. When including all three effects, the predicted energy absorption was less than the response predicted from simulations performed using the von Mises yield criterion and in reasonable agreement with measured data. It is recommended that a combined constitutive model be utilized for the study of materials that show sensitivity to the Bauschinger effect, strain-rate effects, and anisotropy.     

A numerical study on the quasi-static axial crush characteristics of square aluminum–composite hybrid tubes

In this paper, we describe a numerical investigation on the quasi-static axial crush performance of aluminum–composite hybrid tubes containing a filament-wound E-glass fiber-reinforced epoxy over-wrap around square aluminum tubes. The fiber orientation angle in the overwrap was varied between [±30°] and [90°] with respect to the tube’s axis. The quasi-static axial crush resistance of the hybrid tubes are compared in terms of the maximum load, mean crush load, crush energy and specific energy absorption. The deformation modes of these tubes are also described. An empirical equation is proposed for predicting the mean crush force of hybrid tubes.     

Axial crush and bending collapse of an aluminum/GFRP hybrid square tube and its energy absorption capability

In this paper, energy absorption capability of axial crush and bending collapse of aluminum/GFRP hybrid tubes were investigated. Glass fiber–epoxy composite prepregs were wrapped around an aluminum tube and then cured completely in the autoclave under the recommended cure cycle. Bonding process between composite and aluminum tubes was performed by excess resin extracted from the composite tube during curing process. For comparing energy absorption characteristics of the hybrid tube with those of pure aluminum and composite tubes, tests were performed using specimens made of an aluminum alloy and a composite material, respectively.

Failure mechanisms of the hybrid tube under the axial compressive load and the bending load were experimentally investigated. For calculating energy absorption capability of axial crush and bending collapse behaviors of the hybrid tube, the modified plastic hinge collapse model and the modified Kecman's model for hybrid tube were suggested, respectively. Two suggested models for the hybrid tube showed a good agreement with the experimental results.     

Synergistic energy absorption in the axial crush response of filled circular cell honeycombs

In the present investigation, the axial static crush response of circular cell, filled honeycombs is studied. Polycarbonate honeycombs with circular cells are used as the base material. Polyurethane, a soft elastomer is used as the filler material. Filled 3-cell, 7-cell and 19-cell honeycombs were subjected to uniaxial, quasi-static, out-of-plane compressive loading. The experimental results show a synergistic energy absorption event, leading to an amplification of crush energy absorption in the filled honeycombs due to a change in the deformation mode (in comparison against unfilled honeycombs). Moreover, it is seen that the initial failure is a stable collapse unlike the abrupt first failure seen in unfilled honeycombs. An explicit finite element solver is used to quantitatively understand the experimental results, thus validating its usefulness as an engineering design tool.     

Experimental and analytical assessment of axial crushing of circular hybrid tubes under quasi-static load

In the present article, axial crushing behavior of circular aluminum/glass–epoxy hybrid tubes is studied experimentally and analytically. 48 quasi-static axial crushing experiments are carried out on bare metal and hybrid tubes to evaluate the effect of different parameters such as metal and composite wall thicknesses and stacking sequence of composite layers on the crashworthiness characteristics. The specimens are made in two types of layups including angle ply pattern [±θ]_s and multi angle ply pattern (different ply angles). The experimental results reveal that stacking sequence has a considerable effect on crashworthiness characteristics, for example for layup [90/0/0/90], the absorbed energy is more than three times of aluminum tube with the same aluminum wall thickness. Also the aforementioned layup has better energy absorption compared to [90/90/90/90] which has been previously proposed as the best layup.     

Low velocity axial impact crushing performance of empty recyclable metal beverage cans

This paper focuses on the axial impact crushing behaviour of recyclable empty metal beverage cans available in the market. The idea is to make a macro foam (sacrificial cladding structure) out of these cans to protect the main load bearing members of civil engineering structures from the air blast load. Axial drop weight tests have been conducted to understand the crushing characteristics and the corresponding energy absorption of a single empty beverage can in detail. To conduct such tests a small-scale drop weight test set-up has been designed and manufactured. The deformation mechanisms and the corresponding energy absorption of the beverage cans were studied in detail for different initial impact velocities (1.4 m/s, 2.2 m/s, 3.1 m/s, 3.8 m/s, 4.4 m/s and 4.9 m/s). Furthermore, an analytical model is proposed to calculate the crushing parameters of empty metal beverage cans. The results from the analytical model are compared and validated with the experimental results.     

Effect of forming process variables on the crashworthiness of aluminum alloy tubes

This research examines the effect of the tube-bending process on subsequent crashworthiness of aluminum alloy s-rail structures. Through experiments, the effects of bending process parameters, tube initial thickness, thickness changes, work hardening and bend radius on the energy absorption characteristics of s-rail impact structures are assessed. Finite element simulations of the manufacturing and impact testing of s-rail structures are developed to provide additional insight. The deformation history, including strains, thickness changes and residual stresses are transferred from the tube-bending models into the crash models. Through simulation, effects of thickness changes and work hardening on the energy absorption of s-rails are examined. The change in geometrical features of the s-rail due to a different bend radius, on crashworthiness of the s-rail structure was found to play a significant role in offsetting any potential increases in force and energy absorption due to work hardening and thickness changes in the material due to pre-bending. By not accounting for work hardening and thickness changes in the material due to the bending process during the modeling of the crash event, the predicted peak force as well as the energy absorption at the point of tearing was reduced by 25–30% and 18%, respectively.     

Crushing response of composite corrugated tubes to quasi-static axial loading

This paper is devoted to examine the crushing behaviour of axially crushed composite corrugated tubes. Two types of composites were tested, namely, carbon fibre/epoxy in a filament form and glass fibre/epoxy in woven roving form. A series of experiments was conducted for tubes with corrugation angle (β) ranging from 10° to 40°. Typical failure histories of their failure mechanisms are presented and discussed. The results showed that the crushing behaviour of composite corrugated tube is found to be sensitive to the change in corrugation angle and fibre type. Carbon/epoxy tubes with corrugation angle of 40° displayed the highest specific energy absorption capability. It is also found that introducing of corrugation could significantly enhance the energy absorption capability of composite tubes in a uniform manner.     

Cryorolling and warm forming of AA6061 aluminum alloy sheets

Cryorolling is a severe plastic deformation (SPD) process used to obtain ultrafine-grained aluminum alloy sheets along with higher strength and hardness than in conventional cold rolling, but it results in poor formability. An alternative method to improve both strength and formability of cryorolled sheets by warm forming after cryorolling without any post-heat treatment is proposed in this work. The formability of cryorolled AA6061 Al alloy sheets in the warm working temperature range is characterized in terms of forming limit diagrams (FLDs) and limiting dome height (LDH). Strain distributions and thinning in biaxially stretched samples are studied. Hardness of the formed samples is correlated with ultimate tensile strength to estimate post-forming mechanical properties. The limit strains and LDH have been found to be higher than in the case of the conventional processing route (cold rolled, annealed and formed at room temperature), making this hybrid route capable of producing sheet metal parts of aluminum alloys with high strength and formability. In order to combine the advantages of enhanced formability and better post-forming strength than the conventional cold rolled and annealed sheets, warm forming at 250°C has been found to be suitable for this alloy in the temperature range that has been studied.     

Strain rate effects on the compressive property and the energy-absorbing capacity of aluminum alloy foams

The strain rate sensitivity of various relative densities, open-cell aluminum alloy foams fabricated by a powder metallurgical method is investigated under compression loading. Their response to strain rate has been tested over a wide range of strain rates, from 10⁻³ to 2600 s⁻¹ at room temperature. Within this range, the experimental results show that the yield strength and the energy absorbed increase with an increase of strain rate. However, the yield strength of higher relative density foams increases bilinearly with the logarithm of strain rate, and the yield strength of lower relative density foams shows only a linear increase. The compaction strain slightly decreases with an increase of strain rate. The higher relative density aluminum alloy foams are more sensitive to strain rate than the lower relative density foams.     

Influence of notch severity on the impact fracture behavior of aluminum alloy 7055

In this paper, the conjoint influence of notch severity and test temperature on the impact behavior of an Al-Zn-Mg-Cu alloy 7055 in the T7751 microstructural condition is presented and discussed. Notch angles of 45°, 75° and 90° were chosen for a standard charpy impact test specimen containing two notches. For a given angle of the notch the increase in dynamic fracture toughness, with test temperature, is most significant for the least severe of the notches, i.e. 45°. At a given test temperature, the impact toughness of the T7751 microstructure decreased with an increase in notch severity. An increase in notch severity resulted in essentially Mode I dominated fracture at all test temperatures. The influence of localized mixed-mode loading is minimal for the alloy has low dynamic toughness. The impact fracture behavior of the alloy is discussed in light of alloy microstructure, mechanisms governing fracture and the deformation field ahead of a propagating crack.     

Inertia effects in axisymmetrically deformed cylindrical shells under axial impact

The axisymmetric buckling of elastic–plastic cylindrical shells subjected to axial impact are studied using a finite element analysis. This study reveals that shells, subjected to axial impact, are both velocity and mass sensitive, so that larger energies can be absorbed by a shell for high-velocity impacts when decreasing the striking mass. It is shown that the inertia characteristics of the shell, together with the material properties, determine particular patterns of the axial stress wave propagation, thus, causing either dynamic plastic or dynamic progressive buckling to develop during the initial phase of the shell response. Domains of the load parameters, where the different buckling phenomena develop, are obtained for two particular shells. Strain rate effects are also considered when discussing the energy absorbing properties of the shells.     

蜂窝纸板平压实验的研究

在分析蜂窝纸板平压试验结果的基础上,讨论了蜂窝纸板的压溃强度和用能量吸收理论设计蜂窝纸板缓冲垫的方法.     

3D numerical study on wrinkling characteristics in NC bending of aluminum alloy thin-walled tubes with large diameters under multi-die constraints

With an increase in the diameters of aluminum alloy thin-walled tubes (AATTs) and a decrease in their bending radii, wrinkling characteristics and its prediction under multi-die constraints have become a key problem urgently to be solved for improving the forming quality in numerical control (NC) bending of AATTs with large diameters. Thus in this paper, considering the characteristics of the bending processes, based on the ABAQUS software environment, a 3D elastic–plastic finite element model and a wrinkling energy prediction model under multi-die constraints are established and their reliabilities are validated, respectively, in which, the appropriate choosing of forming parameters is achieved to guarantee no excessive thinning and flattening in the processes even if wrinkling borders on occurring. By combining the two models, variation relationships of the maximum wrinkling factor with different compressed deformation zones and forming ratios, and effects of clearances and friction between different dies and tubes on the maximum wrinkling factor are obtained, and then an investigation into the wrinkling characteristics is carried out for the processes. It is found that the larger the diameters of AATTs, the larger the wrinkling sensitive zones (WSZs), and there is a larger possibility of wrinkling in the bending segments of WSZs than in the straight ones; the larger the effects of clearances and friction between different dies and tubes on wrinkling.     

Research on quick superplastic forming technology of aluminum alloy complex components

Quick superplastic forming is a new technology, which combines hot drawing preforming and superplastic forming. It makes full use of the high speed of hot drawing and good formability of superplasticity. This article uses this method to have an experiment of the side wall outer panel of metro vehicle. The results show that the production efficiency is high, the cost is low and the method is feasible. For aluminum alloy complex components, it can solve the difficulties of stamping and low speed of superplasticity.     

Finite element modelling of the progressive crushing of braided composite tubes under axial impact

Composite tubular structures are of interest as viable energy absorbing components in vehicular front rail structures to improve crashworthiness. Desirable tools in designing such structures are models capable of simulating damage growth in composite materials. Our model (CODAM for COmposite DAMage), which is a continuum damage mechanics based model for composite materials with physically based inputs, has shown promise in predicting damage evolution and failure in composites. In this study, the model is used to simulate the damage propagation, failure morphology and energy absorption in triaxially braided composite tubes under axial compression. The model parameters are based on results from standard and specialized material testing and a crack band scaling law is used to minimize mesh sensitivity (or lack of objectivity) of the numerical results. Axial crushing of two-ply and four-ply square tubes with and without the presence of an external plug initiator are simulated in LS-DYNA. Refinements over previous attempts by the authors include the addition of a pre-defined debris wedge, a distinguishing feature in tubes displaying a splaying mode of failure, and representation of delamination using a tiebreak contact interface that allows energy absorption through the un-tying process. It is shown that the model adequately predicts the failure characteristics and energy absorption of the crushing events. Using numerical simulations, the process of damage progression is investigated in detail and energy absorptions in different damage mechanisms are presented quantitatively.     

Effect of triggering and polyurethane foam-filler on axial crushing of natural flax/epoxy composite tubes

In this study, empty and polyurethane-foam filled flax fabric reinforced epoxy composite tubes were longitudinally crushed under quasi-static compression. The effects of foam-filler (density of 160 kg/m³, two diameters of 64 and 86 mm), tube thickness (2, 4 and 6 plies of laminate), and triggering (45° edge chamfering) and the combination of triggering and foam-filler on the crushing characteristics and energy absorption capacity of these tubes were investigated. The test results indicate that the observed primary failure mode was progressive crushing for all the specimens. Foam-filled tubes have better crashworthiness than empty tubes in total absorbed energy, specific absorbed energy and crush force efficiency. The presence of triggering has no significant effect on total absorbed energy and specific absorbed energy of the empty tubes. However, the crush force efficiency of triggered tube is significantly larger compared to the non-triggered one. In addition, the triggering minimises the force variation of the tubes from the average crush force and in turn a more stable progressive crushing is achieved. The foam-filled and triggered tubes have better crashworthiness than the empty tubes in all the aspects. Compared with either triggered or foam-filled tubes, the triggered and foam-filled tubes have larger values in average crush load and crush force efficiency. In terms of total absorbed energy and specific absorbed energy, the triggered and foam-filled tubes have values always larger than those of the tubes with triggering only, but these values are either larger or smaller than the tubes with foam-filler only.     

Investigation of the trivalent-chrome coating on 6063 aluminum alloy

In this work, the green trivalent chromium coating on 6063 aluminum alloy surface was made and studied by means of trivalent chromate compound (KCr(SO₄)₂) as inhibitor. The coating was evaluated in 3.5 wt.% NaCl at room temperature using polarization curve, AC impedance spectroscopy (EIS). The results show that the trivalent chromium compounds treated surface presents better corrosion behavior in chloride media than the original material surface. The morphologies and composition and valence state of the coating were examined by scanning electron microscopy (SEM) and energy dispersive spectrometry (EDS) and X-ray photoelectron spectroscopy (XPS), respectively. The result indicates that the trivalent chromium chemical conversion coating was made on aluminum alloy surface.