Abstract
As foams have become very important in several areas and since characterizing their properties is a crucial task, a finite element simulation model for high-density closed cell foams based on computed tomography (CT) measurements is developed. The model includes realistic microstructural features like cell size distribution due to the utilization of CT data. Moreover, a ‘skin-core-skin’ microstructure resulting from the manufacturing process (injection moulding) of the foams is also considered in the model. The mechanical behaviour of the foam’s core layer under tension and compression load is characterized based on the microstructural model to develop constitutive material models of the foam. These constitutive models enable further mechanical characterization of the foam with less computational effort. Compression and bending test simulations of injection moulded foams with three different densities are validated with corresponding experimental results. Thus, conclusions can be drawn regarding the reliability, applicability and possible further extensions of the high-density foam model.
Highlights
The foam microstructure and foam properties highly depend on the manufacturing process and its parameters.[2,3] The characterization of the foam behaviour can be done computationally
The microstructure of the foam is not modelled in detail and only approximated by a constitutive model resulting in simulation models with low computational effort
A methodology for the generation of microstructural simulation models for high-density foams based on computed tomography (CT) measurement results is introduced
Summary
The foam microstructure and foam properties highly depend on the manufacturing process (e.g. extrusion1) and its parameters.[2,3] The characterization of the foam behaviour can be done computationally. A computed tomography based direct modelling approach for high-density injection moulding foams is developed capturing important microstructural features characteristic for highdensity foams (e.g. skin-core-skin structure). The CT results show that the formed foam cells have an ellipsoidal shape and that due to the manufacturing process a structural foam is produced with compact skin layers and a cellular core. This is already expected from literature.[26,27,28] In Table 1, an overview of the skin and core thickness values of the models for the foams resulting from different opening strokes is given. The density decreases more steeply between the opening strokes 2.3 mm and 2.7 mm than between the opening strokes 2.7 mm and 3 mm
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