铝泡沫填充薄壁结构耐撞可靠性优化设计

泡沫填充薄壁结构能有效地改善汽车薄壁吸能部件的耐撞性。为设计更轻与更有效的吸能结构,并满足汽车安全性设计要求,提出一种新颖的轻质铝泡沫填充双管薄壁结构,并对其耐撞性展开确定性最优化设计。但是,由于薄壁结构的厚度、屈服强度以及铝泡沫的密度等设计参数易受到仿真以及制造误差等不确定性因素的影响,导致确定性最优解收敛于约束边界,从而丢失了应有的使用可靠性要求。因此,提出基于Kriging近似模型与一阶可靠性分析方法的铝泡沫填充结构可靠性最优设计方法,并进一步开展基于参数不确定性的铝泡沫填充结构的耐撞性可靠性优化设计研究。优化结果显示,可靠性最优解不仅远离约束边界,而且较好地满足了铝泡沫填充结构的安全性与可靠性设计要求。     

一种薄壁梁加强结构及其动态抗弯性能分析

针对大客车车身骨架侧墙立柱薄壁梁结构侧翻耐撞性能薄弱的特点,提出了一种等强度贴板加强立柱梁结构.采用LS-DYNA软件对单根悬臂方管在侧向冲击载荷下的动力响应进行了数值模拟,比较分析了不同加强方式下立柱的抗弯性能.结果表明,与薄壁方管、贴板薄壁方管和泡沫铝填充方管相比,等强度贴板方管立柱的吸能性能(或比吸能)显著提高,整体结构在指定冲击位移内充分参与变形,没有出现因局部塌陷而产生的塑性铰,说明这种加强立柱结构是客车侧翻耐撞性立柱的良好型式.     

金属薄壁吸能结构耐撞性研究进展

金属薄壁吸能结构耐撞设计广泛应用于飞机、汽车、铁路列车和轮船等几乎所有交通工具的碰撞动能耗散系统的设计中。本文归纳了轴向载荷作用下薄壁吸能件的变形模式和评价吸能结构耐撞性的参数，叙述了薄壁吸能件轴向力学特性的研究成果，最后分析了薄壁吸能件的主要研究方向。     

自相似仿生层次多胞薄壁管的耐撞性研究及优化

仿生结构以其优异的力学性能被广泛的应用于各种机械结构中。为了提高薄壁结构的耐撞性,将结构仿生学概念引入其结构设计中,提出了一种新型的多胞薄壁吸能结构。采用了理论和数值模拟技术对0~2阶次层次截面的薄壁结构进行对比分析,结果表明:随着仿生层次结构的不断增加,仿生薄壁结构的吸能特性与变形模式进一步提升。同时,结合响应面法和遗传算法对2阶层次截面的薄壁结构进行了优化,并得到了相应的Pareto前沿图,为薄壁结构的耐撞性设计提供了新思路。     

杨桃启发的仿生星形薄壁结构耐撞性研究

薄壁吸能结构在航空航天和交通运输等领域发挥着重要作用。受具有出色抗压特性的杨桃果实启发,设计了仿生星形薄壁结构。通过有限元仿真、实验和理论分析结构变形和吸能机制,讨论截面形状和几何参数对薄壁结构吸能特性的影响。探究了层级设计与加强筋配置对星形薄壁结构耐撞性的优化效果。结果表明,星形薄壁结构具有规则的渐进折叠变形机制,其比吸能、压溃力效率等耐撞性能大幅优于常见截面的薄壁结构,具有良好的工程应用潜力。     

环形梯度多胞结构的多工况耐撞性研究

针对传统多胞薄壁结构在受到冲击时峰值力过大以及在斜向碰撞时易产生全局弯曲而失稳的问题,提出了一种新颖的具有梯度材料分布特性的环形梯度多胞管。提出并推导了环形多胞结构的平均碰撞力的理论模型,并进一步采用实验方法验证了理论模型的可行性。采用数值分析的方法,对比研究环形梯度多胞结构和均匀多胞结构在多角度冲击工况下的吸能特性。研究结果显示：梯度多胞结构比均匀多胞结构具有更好的能量吸收能力和承载特性,尤其在大角度倾斜冲击工况下,梯度多胞结构具有更明显的耐撞性优势;并且,随着梯度指数的增大,梯度多胞结构的峰值力、能量吸收能力都会降低,并呈现逐渐收敛的趋势,梯度厚度区间也对梯度结构的耐撞性有重要影响。     

接触强度和诱导槽对泡沫铝锥管耐撞性分析

针对汽车前纵梁耐撞部件吸能盒结构形式,研究了功能密度梯度泡沫铝填充铝合金锥管在低速冲击下的耐撞性模型优化。通过对泡沫铝填充锥管的轴向低速压溃仿真分析,获得仿真变形状态、载荷及比吸能量对位移的曲线,并对比分析仿真和实验数据,证明仿真模型的有效性。以泡沫铝内核与锥管的接触强度为研究对象,研究其对泡沫铝填充锥管吸能性能的影响。最后提出基于强粘结接触模型的含有诱导槽的功能密度梯度泡沫铝填充模型,并研究其耐撞性。研究表明,具有诱导槽的强粘结泡沫铝填充锥管在碰撞中的峰值载荷更低,载荷变化更平稳,比吸能更大,是一种在汽车制造工程应用中可以考虑的新型吸能结构。     

八边形组合结构薄壁管耐撞性研究

为提高薄壁管件耐撞性,在基础截面薄壁管的基础上,设计了八边形组合结构薄壁管件,并通过理论计算和数值仿真对不同的组合结构以及基础截面薄壁结构进行了轴向压溃动力学分析,从而对比研究了八边形组合薄壁结构的耐撞性能.研究结果表明:组合薄壁结构的整体耐撞性相对于基础截面薄壁结构有着极大的提高,其中比吸能平均提高了63.6％.在组...     

基于高强钢与材料填充的白车身耐撞性轻量化设计

车身结构在碰撞中承担着变形吸能、传递碰撞力以及维持生存空间的作用,基于耐撞性前提下的白车身轻量化设计,有助于提高车辆动力性与燃油经济性,降低排放。将车身结构碰撞形式分解为轴向压溃与横向弯曲两种工况,通过研究不同等级高强钢板与不同类型材料填充组合结构在两种工况下的吸能与抗弯性能,得到针对安全部件与模块的优化结论。将这些结论应用于某量产SUV车身,仿真分析表明该方法不仅提升了车身耐撞性能,同时降低了白车身质量,实现了车身的耐撞性与轻量化设计。     

泡沫填充蜂窝夹层结构汽车吸能盒吸能特性研究

吸能盒是交通事故中尤其是低速碰撞最先进行溃缩吸能的结构,传统吸能盒一般为薄壁方形管结构,随着设计理念的发展,提升吸能能力最主要的两条路线为泡沫填充和复合夹层结构填充。本文分别将EPP泡沫填充六边形,类四边形和类蜂窝夹层,形成复合型泡沫填充蜂窝夹层吸能盒,采用理论分析与数值仿真的方式,以相应的碰撞评价参数对其进行吸能特性研究。结果表明：泡沫填充蜂窝夹层结构吸能盒大大提升了传统吸能盒的吸能能力,并且采用泡沫填充后,蜂窝夹层结构吸能盒的吸能特性也得到了进一步增强。     

Optimization of functionally graded foam-filled conical tubes under axial impact loading

Metallic foams as a filler in thin-walled structures can improve their crashworthiness characteristics. In this article, nonlinear parametric finite element simulations of FGF foam-filled conical tube are developed and the effect of various design parameters such as density grading, number of grading layers and the total mass of FGF tube on resulting mode shapes, specific energy absorption and initial peak load is investigated. Multi design optimization (MDO) technique and the geometrical average method, both are based on FE model are applied to maximize the specific energy absorption and minimize the impact peak force by estimating the best wall thickness and gradient exponential parameter “m” that controls the variation of foam density. The results obtained from the optimizations indicated that functionally graded foam material, with graded density, is a suitable candidate for enhancing the crashworthiness characteristics of the structure compared to uniform density foam.     

Deformation and energy absorption of aluminum foam-filled tubes subjected to oblique loading

Research to quantify the energy absorption of empty and foam-filled tubes under oblique loading with different loading angles and geometry parameters was carried out. Tests on circular tubes made of aluminum alloy AA6063 under quasi-static axial or oblique loading were performed. The collapse behavior of empty, foam-filled single and double tubes was investigated at loading angles of 0°, 5°, 10° and 15° with respect to the longitudinal direction of the tube. The tubes were fixed at both ends and oblique load was realized by applying a load at the upper end of a pair of specimens. When the foam-filled tubular structures subjected to oblique quasi-static loading, some new deformation modes, such as spiral folding mode, irregular extensional folding mode and irregular axi-symmetric or diamond deformation mode, were identified and ascribed to the bending of tubes and shearing of foam filler, as well as the interaction between the tubes and the foam. The energy absorption characteristics of empty and foam-filled single and double tube structures with respect to the load angle and wall thickness are determined. It is found that the energy-absorbing effectiveness factors of the circular tube structures with aluminum foam core are significant higher than those of the empty tubes and the energy absorption capacity of the foam-filled double tubes is better than that of the empty and foam-filled single tubes.     

Parametric study and numerical analysis of empty and foam-filled thin-walled tubes under static and dynamic loadings

In this paper the crushing behavior of thin-walled tubes under static and dynamic loading is investigated. First, a finite element (FE) model for empty thin-walled tube was constructed and validated by available experimental and numerical data. The comparison between the FE results and the existing numerical solutions as well as the available experimental results showed good agreements. Next, a model for the foam was adopted and implemented in an in-house FE code. The implemented isotropic foam model was then used to simulate the behavior of foam-filled tubes under both static and dynamic loadings. Good agreement was observed between the results from the model with those obtained by analytical relations and experimental test data. The validated FE model was then used to conduct a series of parametric studies on foam-filled tapered tubes under static and dynamic loadings. The parametric studies were carried out to determine the effect of different parameters such as the number of oblique sides, foam density and boundary conditions on crushing behavior of rectangular tubes. The characteristic included deformed shapes, load–displacement, fold length and specific energy absorptions.     

泡沫铝填充帽型结构轴向冲击吸能特性的试验研究

利用冲击试验系统,通过试验方法研究了泡沫铝填充帽型结构在轴向冲击工况下的吸能特性。首先进行了泡沫铝、空心帽型结构以及泡沫铝填充帽型结构的轴向冲击试验;然后根据试验结果,对泡沫铝填充帽型结构轴向冲击工况下的吸能特性进行了分析,评估了填充泡沫铝以及应变率对帽型结构吸能特性的影响。试验结果表明, 与空心结构相比,填充泡沫铝之后帽型结构的轴向压缩稳定性和吸能特性有明显的改善;由于材料对应变率敏感, 与准静态压缩相比,结构的吸能特性有一定的提高。     

Experimental studies on the axial crash behavior of aluminum foam-filled hat sections

Drop hammer tests were carried out to study the axial crash behavior of aluminum foam-filled hat sections. First, the axial crash tests of the empty hat sections, aluminum foam and the aluminum foam-filled hat sections were carried out; then, based upon the test results, the axial crash behavior of the aluminum foam-filled hat sections were analyzed. It was found that aluminum foam filling can increase the energy absorption capacities of the hat sections. Compared with the non-filled structures, aluminum foam-filled structures were much more stable and needed less mass to absorb the specified energy. __________ Translated from Chinese Journal of Mechanical Engineering, 2006, 42(4) (in Chinese)     

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.     

圆形子胞驱动的层级柱状结构在轴向载荷下的抗冲击性研究

为了解决单胞薄壁结构能量吸收效率低的缺陷，进一步改善薄壁结构的防护吸能性能，提出一种基于圆形子胞元的层级柱状结构设计方法，建立方形与圆形层级薄壁柱的几何与数值模型，采用试验研究调查了层级柱状结构的轴向抗冲击性能，发现层级柱状结构吸能性能大大优于相同质量下的单胞薄壁结构；此外，进一步数值调查了层级柱状结构的几何参数(薄壁壁厚t、子胞元直径D)对其吸能特性的影响，发现壁厚t对层级柱的吸能特性有积极作用，且壁厚与子胞元直径的比值t/D对结构的变形模式具有决定性作用。因此，研究也形成了基于壁厚与子胞元直径比值t/D的层级柱状结构设计准则。此外，进一步基于超折叠单元理论对层级柱状结构的平均碰撞力展开了理论预测研究，推导了层级柱状结构在渐进折叠模式下平均碰撞力的理论预测模型，进一步揭示了层级柱状结构的变形与吸能机制与平均碰撞力的内在联系，并且，不同壁厚下方形层级与圆形层级柱状结构的理论预测与数值结果具有较好的一致性，从而验证了层级柱状结构的平均碰撞力理论模型的预测精度。研究结果对具有高吸能效率的轻质薄壁结构的设计具有好的指导意义。     

聚氨酯泡沫填充的碳纤维增强复合材料锥管吸能性能数值模拟及试验验证

提出了一种新型的碳纤维增强复合材料（CFRP）填充聚氨酯（PU）泡沫的汽车前部吸能结构，通过材料性能试验获得了PU泡沫、CFRP复合材料的力学性能参数及PU泡沫填充的CFRP锥管的准静态压缩吸能结果。应用LS-DYNA进行复合材料准静态压溃仿真分析，仿真结果与试验结果吻合较好，验证了复合材料填充结构有限元模型和材料模型的正确性，并且发现泡沫填充的CFRP锥管具有良好的吸能性能，填充结构比吸能高于两种材料单独使用时的比吸能之和。