复合材料货舱地板立柱压溃响应试验

复合材料已经在民用飞机结构上得到广泛应用,并逐渐应用到主承力结构中,复合材料的脆性特点给飞机的适坠性设计和评估提出了新的挑战。复合材料机身货舱地板支撑立柱作为坠撞过程中的重要吸能元件,对机身结构抗坠撞性能有重要影响。复合材料货舱地板支撑立柱在压溃失效模式下吸收的能量明显多于整体弯曲失效模式。根据民用飞机复合材料货舱地板立柱的设计需求,对不同试件触发模式、高度、截面形式、截面面积等设计参数变化的T700GC碳纤维/环氧树脂复合材料立柱开展准静态和动态压溃试验,得到立柱吸能特性的关键影响参数和设计因子。      

直升机抗坠毁试验假人下肢动力学性能的计算机仿真研究

下肢动力学性能研究是直升机抗坠毁试验假人研制过程中的重要课题。在对直升机坠撞事故中飞行员下肢损伤分析的基础上,通过建立具有我国50 th百分位飞行员参数特征的假人下肢有限元模型,按试验要求对下肢动力学性能进行仿真分析;将仿真结果分别与假人下肢动力学性能参考指标及试验结果比较,发现该下肢模型具有较好的生物拟合性,表明采用有限元法对假人下肢动力学性能分析的有效性和可行性。由于直升机坠撞事故中人体下肢损伤形式较复杂,该研究对将来能实现多方位碰撞损伤评价的假人下肢动力学性能研究具有一定指导意义,对假人其他部位动力学性能的仿真研究也具有重要参考价值。     

冲击载荷下泡沫铜-聚氨酯的缓冲性能

目的通过冲弯实验,测定泡沫铜-聚氨酯复合材料结构在动载荷作用下的缓冲吸能性能,对比研究该复合材料结构抗高冲击、高过载的性能差异。方法向泡沫铜试件中填充不同体积分数的聚氨酯,按照《金属常温冲击韧性实验法》在夏比冲击试验机上进行冲弯试验,测定试样的吸收功值,从而对比探究该种复合材料的力学性能。结果聚氨酯在试样中所占体积分数为50%时其能量均值相对最大,此时材料韧性较好,且材料抵抗冲击载荷能力较强。结论将聚氨酯填充到开孔泡沫铜材料中可构成一种性能优良的抗冲击吸能结构,其性能优于泡沫铜和聚氨酯单体,在抗高冲击、高过载的军工产业和民用产业中具有广阔的应用前景。     

复合材料机身结构件冲击模拟与吸能特性研究

对具有吸能子地板的全复合材料机身结构进行了垂直向7.9m/s的抗坠毁数值模拟,得到平均加速度、速度及撞击载荷值等动态冲击参数,考虑采用不同的评价方法来评估其抗坠毁特性。并对全复合材料机身结构进行分块设计,考虑在冲击过程中起关键作用的底部结构中加入吸能泡沫,最后利用专业的瞬态动力学软件对有限元设计模型进行了冲击模拟,并与测试结果进行了比较,结果满足抗坠毁设计相应规范要求。计算得到的平均加速度不超过13g,其相对误差不大于11%,撞击载荷最大不超过6kN,坠毁平均负加速度持续时间不超过0.03s,结果较合理。利用本模型可以指导直升机的抗坠毁设计。     

引发方式、铺层对纤维增强复合材料圆柱壳吸能特性影响的冲击试验研究

对作为吸能元件的纤维增强复合材料圆柱壳的吸能特性进行了试验研究。制备了不同铺层角度和不同引发方式的玻璃纤维/聚酯树脂基圆柱壳,通过对该圆柱壳进行动态试验,探求铺层方式和引发方式对该吸能元件吸能效果的影响,以及该复合材料层合壳体压溃过程的破坏机理。     

含不确定性参数的复合材料薄壁结构吸能特性评估方法研究

由于复合材料性能分散度大、加工精度较低,为复合材料薄壁吸能结构引入了不可忽略的不确定性因素,为此,提出了一种含不确定参数的复合材料薄壁结构吸能特性的评估方法并进行了算例研究。复合材料薄壁圆管是一种典型的吸能元件,圆管的壁厚和内径是对其吸能特性有显著影响的特征几何尺寸,考虑了这两个参数的不确定性,在准静态压溃的条件下评估了薄壁圆管的引发比应力和比吸能这两个关键吸能指标。首先,利用区间分布来描述壁厚和内径的不确定性,其次应用有限元方法建立区间内不确定参数和结构吸能特性指标间的二阶响应面函数,最后对响应面函数进行区间摄动从而确定吸能特性指标的分布区间。算例研究结果显示,与比吸能相比,引发比应力受壁厚和内径不确定性的影响更大。此外,相比于内径,壁厚的不确定性对吸能特性影响更显著,因此为获得稳定的结构吸能特性应尽量提高复合材料圆管壁厚的加工精度。     

复合材料波纹梁冲击试验与数值模拟

为了探究复合材料波纹梁的吸能性能,针对铺层形式分别为[(±45)3/(0,90)/(±45)3]、[(±45)8]和[(±45)7]的3种复合材料波纹梁元件,进行了动态冲击试验,得到了吸能载荷-位移曲线,并对其损伤破坏形貌进行了分析。以连续损伤力学为基础,结合改进的Hashin损伤判定准则以及损伤演化规律,提出了针对波纹梁耐撞性损伤分析的刚度退化模型,并基于有限元软件平台开发了适用于波纹梁渐进损伤分析的子程序。对3种不同结构形式的波纹梁进行了渐进失效数值分析,模拟得到了能量评估参数比吸能(SEA)和平均载荷值,并将模拟结果与试验结果进行了对比分析。比较分析了不同薄弱环节复合材料波纹梁的吸能能力。结果表明:波纹梁在冲击载荷作用下发生了渐进压溃失效;平均压溃载荷的相对误差不超过12%,能够满足工程应用要求;薄弱环节的设置需综合考虑复合材料性能和铺层方式等因素。     

直升机抗坠毁座椅吸能器测量装置

介绍了某型直升机座椅抗坠毁试验中吸能器测量装置设计、校准及应用.通过合理的选材和挑选T字型应变片采用全桥的对称粘贴方法设计制作,用静重式力标准机校准.校准结果表明,这种测量装置具有强度高、易安装、操作方便、动态实时采集的优点且满足试验中冲击精度的要求.与同批次座椅抗坠毁试验吸能器静态力学测试数据相吻合,完成某型直升机座...     

泡沫铝相对密度对泡沫铝-聚氨酯复合材料吸能性能的影响

目的通过准静态压缩试验研究泡沫铝-聚氨酯复合材料(AF-PU)的压缩性能,并利用试验数据探究泡沫铝(AF)相对密度对整体材料吸能性能的影响规律。方法首先使用相关仪器和材料制备AF-PU复合材料,其次用相关仪器对其进行准静态压缩试验。结果 AF-PU复合材料通过相关仪器进行准静态压缩试验,计算得到相对应的应力-应变曲线,同时通过计算得到相对应的吸能-应变曲线。当泡沫铝相对密度从5.6%增加到6.7%时,整体复合材料的屈服强度提升了22.18%。在压缩过程中,当复合材料的压缩应变为0.8时,整体复合材料的总吸能增加了70.08%。结论 AF-PU复合材料的吸能性能随着AF相对密度的增加而增强。     

含概率不确定性的复合材料吸能结构优化设计方法研究

由于复合材料力学性能分散度较大、加工精度较低,复合材料薄壁吸能结构具有难以忽略的不确定性。为此,建立了考虑参数不确定性的复合材料薄壁吸能结构优化设计方法,旨在设计阶段识别参数的不确定性,并设计出具有最优吸能特性的薄壁吸能结构;首先,根据使用条件获取设计参数的范围,并利用中心组合实验设计确定设计参数的试验矩阵;然后,计算试验矩阵中每组设计参数吸能特性指标的平均值和标准差;接下来,分别确定不同复合材料薄壁结构设计参数组合与吸能特性指标的均值及标准差之间的响应面方程;最后,结合响应面方程和设计要求将其代入到优化后的数学表达式中,采用序列二次规划算法进行优化求解。以T700/3234复合材料薄壁圆管为研究对象,在规定特征尺寸范围内,分别对规定峰值载荷求比吸能最大,以及对规定峰值载荷求比吸能标准差最小问题,进行了优化求解,验证了所提方法的实用性。     

Progressive crushing of fiber-reinforced composite structural components of a Formula One racing car

The present paper describes an experimental and numerical investigation on energy absorbers for Formula One side impact and steering column impact. The crash tests are performed measuring the load-shortening diagram and the energy absorbed by the structure. A finite element model is then developed using the non-linear, explicit dynamic code LS-DYNA. To set up the numerical model, tubes crushing testing are conducted to determine the material failure modes and to characterise them with LS-DYNA. The results presented in this study show that the composite structural components of the investigated Formula One racing car possess high value of specific absorbed energy and crash load efficiency around 1.1. The finite element simulations accurately predict the overall shape, magnitude and pulse duration in all the types of impact as well as the deformation and failure of the structures. Comparing the numerical data of the specific absorbed energy to the experimental results, the differences are around 10%.     

巷道吸能支护的减震防冲效应分析

冲击地压是煤矿开采的主要动力灾害，巷道吸能支护是防御冲击地压灾害的新型支护方式和有效手段。吸能支护是在刚性支护基础上附加阻尼耗能构件形成的巷道支护，基于巷道顶板与支护相互作用的动力学模型，分析了在巷道刚性支护与吸能支护作用下的顶板-支护系统动力响应，同时就阻尼构件在吸能支护上的分布特征对减震防冲效应的影响进行了分析，研究了阻尼构件在支护中的串联、并联、混联3种分布特征下的支护吸能减震防冲效应。结果表明：相比于刚性支护，吸能支护不仅能有效抑制顶板的冲击响应，还对支护体的冲击响应具有自保护能力；串联吸能支护模式与混联吸能支护模式对顶板冲击位移的控制及支护体加速度的抑制作用相当，且均优于并联吸能支护模式，其中，在串联吸能支护模式下，顶板冲击位移可下降约89%，支护体加速度可下降约55%。进一步优化串联吸能支护模式可知，当采用支护体上端串联布置吸能构件时，构件吸能效果发挥的最好，并且支护体的变形、应力、等效塑性应变变化平稳且幅值较小，同时相比于在下端以及两端串联吸能构件时支护等效塑性应变分别下降约77%和96%。该研究为冲击地压动力灾害的防冲吸能支护动力可靠性设计提供思路。     

Topology optimization for crashworthiness of thin-walled structures under axial crash considering nonlinear plastic buckling and locations of plastic hinges

Although topology optimization is established for linear static problems, more effort is required for solving nonlinear plastic problems. A new topology optimization approach with equivalent static loads (ESLs) is suggested to find the optimum topologies and locations of plastic hinges of thin-walled crash boxes by considering crash-induced deformation, the main crash energy-absorbing mechanism. Together with finite element method crashworthiness analyses, considering all nonlinearities with rate-dependent plasticity, the method was developed using an appropriate time-incremental scheme of ESLs without removing any high values of loads. Analyses show that the crash boxes with optimum topologies have energy-absorbing capabilities equivalent to the original structure. The proposed method is evaluated for two crashes: a crash box at low speed and a double cell subjected to high-speed collision. The results indicate that this method captures nonlinear crushing behaviours and accurate locations of plastic hinges where, if proper reinforcements are made, energy absorption can be enhanced.     

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.     

Innovative Anti Crash Absorber for a Crashworthy Landing Gear

This paper defines an innovative concept to anti-crash absorber in composite material to be integrated on the landing gear as an energy-absorbing device in crash conditions to absorb the impact energy. A composite cylinder tube in carbon fiber material is installed coaxially to the shock absorber cylinder and, in an emergency landing gear condition, collapses in order to enhance the energy absorption performance of the landing system. This mechanism has been developed as an alternative solution to a high-pressure chamber installed on the Agusta A129 CBT helicopter, which can be considered dangerous when the helicopter operates in hard and/or crash landing. The characteristics of the anti-crash device are presented and the structural layout of a crashworthy landing gear adopting the developed additional energy absorbing stage is outlined. Experimental and numerical results relevant to the material characterization and the force peaks evaluation of the system development are reported. The anti-crash prototype was designed, analysed, optimized, made and finally the potential performances of a landing gear with the additional anti-crash absorber system are tested by drop test and then correlated with a similar test without the anti-crash system, showing that appreciable energy absorbing capabilities and efficiencies can be obtained in crash conditions.     

Multiobjective optimization of multi-cell sections for the crashworthiness design

Plastic deformation of structures absorbs substantial kinetic energy when impact occurs. For this reason, energy-absorbing components have been extensively used in the structural design of vehicles to intentionally absorb a large portion of crash energy to reduce the severe injury of occupants. On the other hand, high peak crushing force may to a certain extent indicate the risk of structural integrity and biomechanical damage of occupants. For this reason, it is of great significance to maximize the energy absorption and minimize the peak force by seeking for optimal design of these components. This paper aims to design the multi-cell cross-sectional thin-walled columns with these two crashworthiness criteria. An explicit finite element analysis (FEA) is used to derive higher-order response surfaces for these two objectives. Both the single-objective and multi-objective optimizations are performed for the single, double, triple and quadruple cell sectional columns under longitudinal impact loading. A comparative analysis is consequently given to explore the relationship between these two design criteria with the different optimization formulations.     

Progressive failure modelling of woven carbon composite under impact

The design of composite structures or components, subject to extreme loading conditions, such as crash, blast, etc. requires a fundamental understanding of the deterioration mechanism within the composite meso-structure. Existing predictive techniques for the analysis of composite structures and components near and beyond their ultimate strength are either based on simple scalar stress functions, or use very complex damage formulations with many material constants, some of which may be difficult to characterise. This paper presents a simple damage mechanics based progressive failure model for thin woven carbon composites under impact loading. The approach is based on an unconventional thermodynamic maximum energy dissipation approach, which entails controlling damage evolution and hence energy dissipation per second, rather than damage. The method has been implemented into the explicit dynamic finite element code DYNA3D. Numerical simulation results using the proposed model are compared with two experimental impact tests.The analysis methodology proposed in this paper reflects a very simple, but effective technique that can be used to model a wide range of problems from extreme events, such as crash or blast, to birdstrike, when tearing and perforation are major failure mechanisms. As damage is cumulative, the technique allows initial or/and post-impact static loads to be applied to the composite structure or component, thus allowing a cradle-to-grave design methodology.     

Numerical investigation of a crash test of a composite helicopter subfloor structure

Composite energy-absorbing aircraft structures are being studied within a European Commission research programme (CRASURV – Design for Crash Survivability). One of the aims of the project is to evaluate the current capabilities of crashworthiness simulation codes for modelling future composite primary structures. In this paper, a detailed analysis is presented of a generic module of a composite helicopter subfloor structure, subjected to crash loading. The analysis is performed with the explicit finite element code PAM-CRASH and is compared with the results of a drop test. It has been found that pre-test simulations with only coupon data as input are capable of providing a reasonable overall representation, but to closely match the behaviour of the test, a significant amount of post-test work is required. The calibration of the post-failure material properties proved to be more crucial than the behaviour up to initial failure. The representation of fabric materials was found to be inadequate and a new fabric material model is under development as a result. The importance of modelling frictional effects was highlighted, and a mesh density study showed the model to be robust over a range of mesh densities.     

Data based models for automobile side impact analysis and design evaluation

Occupant protection during side impacts is a very important consideration in automobile design. To ensure occupant protection. physical tests as well as simulation using analytical models are extensively used in the early phases of design. Analytical models for side impact simulation can be developed directly from the crash measurement data and the physical insight of the crash event. In this paper, uncoupled lumped parameter models for the automobile structure and the test dummy are developed based on the study of distribution of crash energy. The model parameters are estimated using a Kalman filter estimator in a constrained environment. The estimation approach is verified using simulated data as well as test data. The modeling and application of the data based model is demonstrated in the actual design environment with an example. The data based model is shown to be very useful in understanding the contribution of various components in the overall crash performance, evaluating design trade-offs and developing component level performance targets.