粉煤灰漂珠/聚氨酯复合泡沫铝材料压缩性能与本构关系研究

采用压力渗透法制备出了铝基复合泡沫材料,填充材料是以粉煤灰漂珠为主要组分、硬质聚氨酯泡沫为粘结剂的复合泡沫材料.通过准静态实验和分离式霍普金森压杆(Split Hopkinson pressure bar,SHPB)动态压缩的方法研究了复合泡沫铝的压缩力学响应,然后建立了动态本构关系.研究表明,复合泡沫铝的压缩应力-应变曲线与其它泡沫材料的应力-应变曲线类似,文中的两种铝基复合泡沫具有应变率效应,复合泡沫铝较密度相近未填充前的泡沫铝基具有更高的压缩强度与能量吸收能力.但由于漂珠尺寸的不同,导致两种复合泡沫铝的动态压缩结果不尽相同,且小颗粒复合泡沫铝在动态冲击下吸能效果最好.在本研究实验的应变率和密度范围内,本文建立的本构模型曲线与实验曲线吻合较好.     

Dynamic indentation and penetration of aluminium foams

Failure of metal foams caused by dynamic indentation and penetration is very common in practice, such as light-weight structural sandwich panels, packing materials and energy absorbing devices. Rational application of these materials requires a sound understanding of deformation and energy absorption mechanisms of the aluminium foams as well as the effect of impact velocity. In this study, following experimental investigations into compression, tension, sharing and indentation of CYMAT aluminium foams of various densities, a finite element (FE) analysis using ABAQUS is conducted for dynamic indentation process of aluminium foams under a rigid, flat-headed indenter. Two methods of applying impact velocities are considered: the indenter is pushed into the foam at a constant velocity through the whole process or with an initial velocity which then decreases with indentation. Two energy dissipation mechanisms are considered: compression of the foam ahead of the indenter and fracture along the indenter edge. Effect of impact velocity is noted on the size of a localized deformation and the total energy absorbed. A plastic structural shock theory developed by previous researchers is applied to calculate the resistance force with indentation depth during indentation process and fair agreement is obtained between the analytical and numerical results.     

Application of a continuum constitutive model to metallic foam DEN-specimens in compression

The behavior of double-edge notched specimens of metallic foams in compression is studied numerically. To model the constitutive behavior of the metallic foam, a recently developed phenomenological, pressure-sensitive yield surface [1] is used. Compressive yielding in response to hydrostatic stress is incorporated through a dependence on the plastic Poisson ratio ν^p. Results are presented in terms of limit load F_lim, as a function of notch depth, a/W, and the plastic Poisson ratio ν^p. For incompressible plastic behavior, ν^p=0.5, the results show notch-strengthening due to constrained plastic deformation near the crack/notch-tip. For fully compressible plastic behavior (no lateral expansion on uniaxial compression, ν^p=0), no notch-effect is observed. The validity of using a continuum model for the analysis of metallic foam notched specimens is discussed.     

Yield and buckling behavior of Kelvin open-cell foams subjected to uniaxial compression

This study analyzes the yield and buckling behavior of Kelvin open-cell foams subjected to uniaxial compression. A homogenization theory of the updated Lagrangian type is applied to cubic unit cells and cell aggregates in the Kelvin foam model. Macroscopic instability and microscopic bifurcation are thus incrementally examined under uniaxial compression. The analysis is performed by taking into account the non-uniformity of strut cross-sectional areas and the strain hardening-softening behavior of struts that were observed in experiments on open-cell 6101-T6 aluminum alloy foams. It is shown that macroscopic instability primarily occurs as a consequence of the strain hardening-softening behavior of struts. It is further shown that the macroscopic instability stress obtained has (3/2)th power dependence on relative density as predicted in the Gibson-Ashby relation.     

Torsional crushing of foam-filled thin-walled square columns

Torsional crushing behavior of foam-filled thin-walled square columns were investigated analytically, numerically and experimentally. The lower and upper bounds on the torsional resistance of foam-filled columns were established analytically. Numerical simulations were carried out and showed that the presence of the filler changes the torsional collapse mechanism and gives rise to higher order sectional collapse modes, which results in a higher torsional resistance. Torsional experiments were performed and results were compared to the analytical and numerical solutions with reasonably good agreement. It was found that bonding of the foam to the walls changes the deformation mode by spreading deformation over the whole length. The corresponding torsional resistance is also larger for the first 40° of rotation. It is concluded that fitting prismatic members with the aluminum foam of a density ranging from 0.14 to 0.28 g/cm³ can double the energy absorption of a given member.     

粉煤灰漂珠/聚氨酯复合泡沫铝材料压缩性能与本构关系研究

采用压力渗透法制备出了铝基复合泡沫材料,填充材料是以粉煤灰漂珠为主要组分、硬质聚氨酯泡沫为粘结剂的复合泡沫材料.通过准静态实验和分离式霍普金森压杆(Split Hopkinson pressure bar,SHPB)动态压缩的方法研究了复合泡沫铝的压缩力学响应,然后建立了动态本构关系.研究表明,复合泡沫铝的压缩应力-应变曲线与其它泡沫材料的应力-应变曲线类似,文中的两种铝基复合泡沫具有应变率效应,复合泡沫铝较密度相近未填充前的泡沫铝基具有更高的压缩强度与能量吸收能力.但由于漂珠尺寸的不同,导致两种复合泡沫铝的动态压缩结果不尽相同,且小颗粒复合泡沫铝在动态冲击下吸能效果最好.在本研究实验的应变率和密度范围内,本文建立的本构模型曲线与实验曲线吻合较好.     

Confocal imaging and second-order stereological analysis of a liquid foam

Foam structures are found in diverse fields of study; the structure of fire-fighting foam, upholstery foams and even the head on a pint of beer all share detailed similarities in their microstructure and dynamics. Despite impressive developments in the theory of two-dimensional foams the challenge in future will be to analyse and model the dynamics of three-dimensional foams. However, the myriad of gas/liquid interfaces in an aqueous foam make direct imaging of their structure difficult. In this study we circumvent this problem by using fluorescence confocal microscopy to acquire three-dimensional images of the structure of a coarsening aqueous foam. A stable aqueous foam was created by mixing commercial shaving foam with ethanol and a small amount of fluorescein solution. The foam was imaged in fluorescence mode such that the liquid fraction of the foam, containing the fluorescent dye, could be seen in optical sections. These images could be acquired in three-dimensional stacks of optical sections up to a depth of about 200 μm. Single images were also acquired as a time series. The time series of single optical section images clearly show the dynamics of the foam. Early images show a structure made mainly of spherical bubbles; later images show the polyhedral structure of the foam which coarsens as a function of time. The polyhedral nature of the foams is shown particularly clearly in stereo pair images of the three-dimensional image sets. The three-dimensional images of the foams were also analysed using second-order stereology (statistical summaries of spatial distribution). The x, y and z coordinates of the foam vertices were extracted from the images and used to compute the nearest neighbour (G-function) and reduced second moment (K-function) statistics. These statistics allow quantification of the range of length scales found in the foams. These results form part of an ongoing study of the coarsening of aqueous foams.     

A laser spectrometer of field-asymmetric ion mobility

A method for analyzing a substance has been experimentally tested. The method combines the field-asymmetric ion mobility spectrometry and laser ionization of molecules under atmospheric pressure. Pulsed radiation of the fourth harmonic of an YAG: Nd³⁺ laser (λ = 266 nm) and a spectrometer with a cylindrical analysis camera were used. The results of detecting nitrocompounds—trinitrotoluene, cyclotrimethylenetrinitramine (hexogen, RDX), etc.—are presented. The experimental detection limits of the spectrometer are 5 × 10⁻¹⁵ g/cm³ (cyclotrimethylenetrinitramine) and ≤3 × 10⁻¹⁵ g/cm³ (trinitrotoluene).     

A simple approach to estimate failure surface of polymer and aluminum foams under multiaxial loads

From mechanical point of view, it is required to have a criterion for evaluating the failure of cellular solids (foams) under multiaxial loads. Well-documented experimental results in the literature show foams could fail by several mechanisms, e.g., elastic buckling, plastic yielding, brittle crushing or brittle fracture. In the previous years, both theoretical and phenomenological approaches have been applied to obtain the failure surface of various foams. The purpose of this paper is to present a simple approach to estimate the complete failure surface of “non-textured” foams. The predicted results of polymer and aluminum foams are compared with the experimental results reported in the literature. It is found that three selected tests will be sufficient to estimate the complete failure surface of a foam. The recommended testing stress states are σ₁=σ₂=σ₃>0, σ₁=σ₂=σ₃<0, and σ₁=−σ₂=−σ₃ (or σ₁=−σ₂, σ₃=0).     

Microcellular injection molding process for producing lightweight thermoplastic polyurethane with customizable properties

A three-stage molding process involving microcellular injection molding with core retraction and an “out-of-mold” expansion was developed to manufacture thermoplastic polyurethane into lightweight foams of varying local densities, microstructures, and mechanical properties in the same microcellular injection molded part. Two stages of cavity expansion through sequential core retractions and a third expansion in a separate mold at an elevated temperature were carried out. The densities varied from 0.25 to 0.42 g/cm³ (77% to 62% weight reduction). The mechanical properties varied as well. Cyclic compressive strengths and hysteresis loss ratios, together with the microstructures, were characterized and reported.     

A new hardening rule for metallic foam plasticity

Metallic foams are a class of porous materials widely used in the industry because of their advantages. In recent years, extensive studies on the behavior of these materials have been conducted. Several constitutive equations have also been presented and applied. This study proposes a new constitutive equation that predicts metallic foam behavior using the stress–strain curve in uniaxial compression. The proposed model offers a new functionality for work hardening and is evaluated for both isotropic and combined hardening. The constitutive equations are implemented in MATLAB and integrated using return mapping algorithm. The material parameters are identified using genetic algorithm and through a comparison of the experimental and numerical results. The aluminum foams discussed in this paper are the commercially available types, Foaminal and Alporas. The comparison of numerical and experimental results indicate that this new constitutive equation predicts foam behavior in a reasonable manner. Moreover, a good agreement is observed between the experimental and computational curves.     

A constitutive model for polyurethane foam with strain rate sensitivity

The present work investigates the strain rate dependent behavior of polyurethane foams and formulates a new constitutive model in order to improve the fit of the experimental data at various strain rates. The model has seven parameters that are decided by quasi-static compression tests at two strain rates. Two models for low and high density polyurethane foams are shown to give stress strain relation at various strain rates. Dynamic compression tests were carried out to give stress strain data at high strain rate and the results are compared with those of the constitutive model.     

Simulation numérique du confort de sièges d'automobiles : comportement mécanique 3D de mousses de polyuréthanne ; optimisation 2D d'un profil simplifié de siège

Numerical simulation of automotive seat comfort 3D mechanical behaviour of the polyurethane foam; 2D optimisation of a simplified profile of seat. In this article, mechanical behaviour of different polyurethane (PU) foams is investigated. Focus has been placed on the time-dependent behaviour under large deformation. Selected experimental results from uniaxial compressive tests (cycling and relaxation), and simple shear tests are presented. A phenomenological constitutive law is developed and used to model these polymeric foams. Numerical validation of the constitutive model is also described thanks to the simulation of an indentation test. The actual purpose of this study is the simulation of a SAE mannequin sitting in a complete car seat and the optimisation of its geometric form for better comfort.     

Constitutive modeling for Ti-6Al-4V alloy machining based on the SHPB tests and simulation

A constitutive model is critical for the prediction accuracy of a metal cutting simulation. The highest strain rate involved in the cutting process can be in the range of 10~4–10~6 s~(–1). Flow stresses at high strain rates are close to that of cutting are difficult to test via experiments. Split Hopkinson compression bar(SHPB) technology is used to study the deformation behavior of Ti-6Al-4V alloy at strain rates of 10~(–4)–10~4s~(–1). The Johnson Cook(JC) model was applied to characterize the flow stresses of the SHPB tests at various conditions. The parameters of the JC model are optimized by using a genetic algorithm technology. The JC plastic model and the energy density-based ductile failure criteria are adopted in the proposed SHPB finite element simulation model. The simulated flow stresses and the failure characteristics, such as the cracks along the adiabatic shear bands agree well with the experimental results. Afterwards, the SHPB simulation is used to simulate higher strain rate(approximately 3×10~4 s~(–1)) conditions by minimizing the size of the specimen. The JC model parameters covering higher strain rate conditions which are close to the deformation condition in cutting were calculated based on the flow stresses obtained by using the SHPB tests(10~(–4)–10~4 s~(–1)) and simulation(up to 3×10~4 s~(–1)). The cutting simulation using the constitutive parameters is validated by the measured forces and chip morphology. The constitutive model and parameters for high strain rate conditions that are identical to those of cutting were obtained based on the SHPB tests and simulation.     

Indentation of foamed plastics

When a low density foam is indented, it is found that the indentation hardness is about equal to the yield strength of the foam in compression. In this, foams differ from fully dense materials which, when plastic, exhibit a hardness which is about three times larger than the yield strength. This is because the foam is compressible: under the indent, a column of foam collapses, in a way which is hardly influenced by the surrounding material. This paper reports analyses of the indentation of compressible foams by cylindrical and spherical indenters, which reasonably account for measurements of the indentation hardness and the shape of the plastic zone beneath the indenter, in polyurethane foams. The results are relevant to the understanding of low density foams and woods, be they elastic, plastic or brittle.     

The plastic collapse and energy absorption capacity of egg-box panels

The plastic collapse response of aluminium egg-box panels subjected to out-of-plane compression has been measured and modelled. It is observed that the collapse strength and energy absorption are sensitive to the level of in-plane constraint, with collapse dictated either by plastic buckling or by a travelling plastic knuckle mechanism. Drop weight tests have been performed at speeds of up to 6 ms⁻¹, and an elevation in strength with impact velocity is noted. A 3D finite element shell model is needed in order to reproduce the observed behaviours. Additional calculations using an axisymmetric finite element model give the correct collapse modes but are less accurate than the more sophisticated 3D model. The finite element simulations suggest that the observed velocity dependence of strength is primarily due to strain-rate sensitivity of the aluminium sheet, with material inertia playing a negligible role. Finally, it is shown that the energy absorption capacity of the egg-box material is comparable to that of metallic foams.     

Forging of cast Mg-3Sn-2Ca-0.4Al-0.4Si magnesium alloy using processing map

Mg-3Sn-2Ca (TX32) alloy has good creep resistance but limited workability. Minor amounts of Al and Si have been added to TX32 for improving its hot workability. The processing map for the TX32-0.4Al-0.4Si alloy exhibited two workability domains in the temperature and strain rate ranges: (1) 310-415°C/0.0003-0.003 s^-1 and (2) 430-500°C/0.003-3 s^-1. The alloy exhibited flow instability at temperatures < 350°C at strain rates > 0.01 s^-1. The alloy has been forged to produce a cup shape component to validate these findings of processing map. Finite-element (FE) simulation has been performed for obtaining the local variations of strain and strain rate within the forging. The microstructures of the forged components under the optimal domain conditions revealed dynamically recrystallized grains, and those forged in the flow instability regime have fractured and exhibited flow localization bands and cracks. The experimental loadstroke curves correlated well with those obtained by FE simulation.

     

An experimental study on the ultrasonic machining characteristics of engineering ceramics

Engineering ceramics have many unique characteristics both in mechanical and physical properties such as high temperature hardness, high thermal, chemical and electrical resistance. However, its machinability is very poor in conventional machining due to its high hardness and severe tool wear. In the current experimental study, alumina (Al₂O₃) was ultrasonically machined using SiC abrasives under various machining conditions to investigate the material removal rate and surface quality of the machined samples. Under the applied amplitude of 0.02 mm, 27 kHz frequency, three slurry ratios of 1:1, 1:3 and 1:5 with different tool shapes and applied static pressure levels, the machining was conducted. Using the mesh number of 240 abrasive, slurry ratio of 1:1 and static pressure of 2.5 kg/cm², maximum material removal rate of 18.97 mm³/min was achieved. With mesh number of 600 SiC abrasives and static pressure of 3.0 kg/cm², best surface roughness of 0.76 pm Ra was obtained.     

Dry sliding wear behaviour of Al(Mg)/Al2O3 interpenetrating composites produced by a pressureless infiltration technique

Aluminium alloys, reinforced with ceramic particles or fibres, are desired materials in high performance applications due to their superior properties. In this paper, gel-cast Al₂O₃ foams were pressurelessly infiltrated using an Al–8 wt.% Mg alloy. The wear rates of the alloy and the Al(Mg)/Al₂O₃ interpenetrating composites were tested under dry sliding conditions; effects of Al₂O₃ foam density and cell size on the composite wear resistance under different loads and sliding distances were investigated. A ‘ploughing’ mechanism was observed in all the composites after an initial 250 m sliding distance, whilst the composites with the higher foam density show a ‘two-stage’ wear with sliding distance. The decrease in the wear rate in the second stage in the latter is attributed to an Al₂O₃ network protruding out of the worn surface, which protects the direct wear of the Al(Mg) alloy by the counter ball. Within the range studied, a larger cell size is preferred for better wear resistance.     

Tribological Properties of Phosphor Bronze and Nanocrystalline Nickel Coatings Under PAO + MoDTC and Ionic Liquid Lubricated Condition

The friction and wear properties of phosphor bronze and nanocrystalline nickel coatings were evaluated using a reciprocating ball-on-plates UMT-2MT sliding tester lubricated with ionic liquid and poly-alpha-olefin containing molybdenum dialkyl dithiocarbamate, respectively. The morphologies of the worn surfaces for the phosphor bronze and nanocrystalline nickel coatings were observed using a scanning electron microscope. The chemical states of several typical elements on the worn surfaces were examined by means of X-ray photoelectron spectroscopy. Results show that the phosphor bronze and nanocrystalline nickel coatings exhibited quite different tribological behaviors under different lubricants. Phosphor bronze plate shows higher friction coefficient (0.14) and wear rate (3.2 × 10⁻⁵ mm³/Nm) than nanocrystalline nickel coatings (average friction coefficient is 0.097, wear rate is 1.75 × 10⁻⁶ mm³/Nm) under poly-alpha-olefin containing molybdenum dialkyl dithiocarbamate lubricated conditions. The excellent tribological performance of nanocrystalline nickel coatings under above lubricant can be attributed to the formation of MoS₂ and MoO₃ on the sliding surface. a quite a number of C, O and F products on worn surface of phosphor bronze than NC nickel coatings can improve anti-wear properties while using ionic liquid as lubricant.