Mechanical properties and energy absorbing capabilities of Z-pinned aluminum foam sandwich

Aluminum foam sandwich (AFS) structures are suitable for impact protection in lightweight structural components due to their specific energy absorption capability under compression. However, tailoring the deformation patterns of the foam cells is a difficult task due to the randomness of their internal architecture. The objective of this study is to analyze the effect of embedding aluminum pins into an AFS panel (Z-pinning) to better control its deformation pattern and improve its energy absorption capability. This study considers a closed-cell AFS panel and analyzes the effect of multi-pin layout parallel to the direction of the uniaxial compressive loading. The results of the experimental tests on the reference (without Z-pinning) AFS are utilized to develop numerical models for the reference and Z-pinned AFS structures. Physical experiments and numerical simulations are carried out to demonstrate the advantages of Z-pinning with aluminum pins. The results exhibit a significant increase in elastic modulus, plateau stress and energy absorption capability of the Z-pinned samples. Also, the effect of the pin size and Z-pinning layout on the mechanical performance of the Z-pinned AFS is also investigated using numerical simulations

Modelling and characterization of cell collapse in aluminium foams during dynamic loading

Plate-impact experiments have been conducted to investigate the elastic–plastic behaviour of shock wave propagation and pore collapse mechanisms of closed-cell aluminium foams. FE modelling using a meso-scale approach has been carried out with the FE software ABAQUS/Explicit. A micro-computed tomography-based foam geometry has been developed and microstructural changes with time have been investigated to explore the effects of wave propagation. Special attention has been given to the pore collapse mechanism. The effect of velocity variations on deformation has been elucidated with three different impact conditions using the plate-impact method. Free surface velocity (ufs) was measured on the rear of the sample to understand the evolution of the compaction. At low impact velocities, the free-surface velocity increased gradually, whereas an abrupt rise of free-surface velocity was found at an impact velocity of 845 m/s with a copper flyer-plate which correlates with the appearance of shock. A good correlation was found between experimental results and FE predictions

Large strain compressive response of 2-D periodic representative volume element for random foam microstructures

A numerical investigation has been conducted to determine the influence of Representative Volume Element (RVE) size and degree of irregularity of polymer foam microstructure on its compressive mechanical properties, including stiffness, plateau stress and onset strain of densification. Periodic two-dimensional RVEs have been generated using a Voronoi-based numerical algorithm and compressed. Importantly, self-contact of the foam’s internal microstructure has been incorporated through the use of shell elements, allowing simulation of the foam well into the densification stage of compression; strains of up to 80 percent are applied. Results suggest that the stiffness of the foam RVE is relatively insensitive to RVE size but tends to soften as the degree of irregularity increases. Both the shape of the plateau stress and the onset strain of densification are sensitive to both the RVE size and degree of irregularity. Increasing the RVE size and decreasing the degree of irregularity both tend to result in a decrease of the gradient of the plateau region, while increasing the RVE size and degree of irregularity both tend to decrease the onset strain of densification. Finally, a method of predicting the onset strain of densification to an accuracy of about 10 per cent, while reducing the computational cost by two orders of magnitude is suggested

A multi-scale approach for the optimum design of sandwich plates with honeycomb core. Part I: homogenisation of core properties

This work deals with the problem of the optimum design of a sandwich panel. The design process is based on a general two-level optimisation strategy involving different scales: the meso-scale for both the unit cell of the core and the constitutive layer of the laminated skins and the macro-scale for the whole panel. Concerning the meso-scale of the honeycomb core, an appropriate model of the unit cell able to properly provide its effective elastic properties (to be used at the macro-scale) must be conceived. To this purpose, in this first paper, we present the numerical homogenisation technique as well as the related finite element model of the unit cell which makes use of solid elements instead of the usual shell ones. A numerical study to determine the effective properties of the honeycomb along with a comparison with existing models and a sensitive analysis in terms of the geometric parameters of the unit cell have been conducted. Numerical results show that shell-based models are no longer adapted to evaluate the core properties, mostly in the context of an optimisation procedure where the parameters of the unit cell can get values that go beyond the limits imposed by a 2D model

A dynamic modelling of safety nets

The nonlinear dynamic modelling of safety net systems is approached at different scales. For this purpose, the fundamental rope dynamic tests are the reference for two basic tools. One hand an anaytical bidimensional model with explicit geometrical nonlinearity and bilnear material law is proposed for preliminary design. On the other hand, a nonlinear explicit finite element is defined for numerical modelling of net systems. Semi-scale and full scale dynamic tests are performed to validate complete finite element models, suitable for global qualification of safety systems. The direct applications of these tools deal with explicit certification of safety systems for high-speed sport, such as downhill competitions

A multi-scale approach for the optimum design of sandwich plates with honeycomb core. Part II: the optimisation strategy

This work deals with the problem of the optimum design of a sandwich panel. The design strategy that we propose is a numerical optimisation procedure that does not make any simplifying assumption to obtain a true global optimum configuration of the system. To face the design of the sandwich structure at both meso and macro scales, we use a two-level optimisation strategy: at the first level we determine the optimal geometry of the unit cell of the core together with the material and geometric parameters of the laminated skins, while at the second level we determine the optimal skins lay-up giving the geometrical and material parameters issued from the first level. The two-level strategy relies both on the use of the polar formalism for the description of the anisotropic behaviour of the laminates and on the use of a genetic algorithm as optimisation tool to perform the solution search. To prove its effectiveness, we apply our strategy to the least-weight design of a sandwich plate, satisfying several constraints: on the first buckling load, on the positive-definiteness of the stiffness tensor of the core, on the ratio between skins and core thickness and on the admissible moduli for the laminated skins

The modelling of oxide film entrainment in casting systems using computational modelling

As Campbell stated in 2006, “the use of entrainment models to optimise filling systems designs for castings has huge commercial potential that has so far being neglected by modellers”. In this paper a methodology using computational modelling to define entraining events and track the entrained oxide films is presented. Research has shown that these oxide films present within the casting volume are highly detrimental to casting integrity, thus their entrainment during mould filling is especially undesirable. The method developed for the modelling of oxide entrainment has been validated against previously published data by Green and Campbell (1994) [31]. The validation shows good quantitative correlation with experimental data. However there is scope for further development which has the potential to both improve the accuracy and further validate the technique

Optimal design of sandwich plates with honeycomb core

This work deals with the problem of the optimum design of a sandwich structure composed of two laminated skins and a honeycomb core. The goal is to propose a numerical optimisation procedure that does not make any simplifying hypothesis in order to obtain a true global optimal solution for the considered problem. In order to face the design of the sandwich structure at both meso and macro scales, we use a two-level optimisation strategy. At the first level, we determine the optimum geometry of the unit cell together with the material and geometric parameters of the laminated skins, while at the second level we determine the optimal skins lay-up giving the geometrical and material parameters issued from the first level. We will illustrate the application of our strategy to the least-weight design of a sandwich plate submitted to several constraints: on the first buckling load, on the positive-definiteness of the stiffness tensor of the core, on the ratio between skins and core thickness and on the admissible moduli for the laminated skins

Diffuse Interface Models for Metal Foams

le interest because of their potential applications in many fields of the industry. To produce a metal foam, a well-established process is starting with a molten metal, then introducing blowing agents to create gas bubbles inside the metal. In this work we use COMSOL Multiphysics® and apply the diffuse interface methods of the phase field technique, in order to model the properties of metal foams and describe the movement of the gas-liquid interfaces. A metal foam represented by a number of bubbles moving in a laminar flow is modeled and simulated. Surface tension effects are considered and repulsive forces between neighboring bubbles are expressed through the disjoining pressure. The numerical results show that diffuse interface methods are effective to model this kind of complex phenomena and that fundamental mechanisms due to surface tension effects an