Energy Absorbing Structures Research Articles

Research on the energy absorption performance of lattice filling structures based on homogenization analysis technique

The lattice structure has great application prospects in the field of energy absorption, but the high cost of numerical analysis makes it difficult to carry out related structural designs. Therefore, this article studies the feasibility of the homogenization analysis technique for the analysis of energy absorption processes in lattice-filled structures. In the study, compression experiments and numerical simulations were conducted for four different types of unit cells (including periodic truss-lattice cells and triply periodic minimal surface (TPMS cells). In the experiments, two compression samples with different numbers of periods were designed for the same unit cell structure. The research shows that the homogenized numerical model takes a lot less time to run than the classical beam and shell element models. The results of the simulation are also in line with the data from the experiments. On the other hand, the material curve constructed based on a small number of unit cell samples has excellent analytical accuracy. This means that relevant research can obtain the material experimental data required for homogenized analysis using lattice samples with low manufacturing costs. Understanding these phenomena can provide a basis for the design of energy absorption structures.

Failure mechanism and crashworthiness optimization of variable stiffness nested origami crash box

In recent years, the study of the crashworthiness of lightweight and efficient thin-walled energy-absorbing structures has received increasing attention. In this work, 3D printing technology was adopted to create a nested origami crash box with stiffness variation, which was made of short carbon fiber reinforced nylon material. The structure effectively inhibits the development of failure behavior of short carbon fiber-reinforced nylon origami crash box due to material brittleness. The quasi-static compression experiment results indicate that compared to origami crash box, nested origami crash box improves by 40% in specific energy absorption and 50% in crash force efficiency, while the initial peak crushing force remains unchanged. The effects of three key geometrical parameters, namely dihedral angle, distance between tubes, and height difference on the damage mechanism of the nested origami crash box are discussed in detail using the finite element method, and the response surface model combined with the non-dominated sorting genetic algorithm II is used for multi-objective optimization. In this work, the concepts of origami theory and nested systems are integrated for the first time, aiming to achieve a stable and efficient energy-absorbing deformation mode by precisely modulating the stress transfer path of the structure and its stiffness. This work provides new ideas for the design and fabrication of novel lightweight energy-absorption boxes.

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH2) and sodium carbonate (Na2CO3) as foaming agents, with varying mixing ratios were performed under different processing conditions. The results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent’s laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

Investigation on the energy absorption characteristics of novel graded auxetic re-entrant honeycombs

In this work, innovative graded auxetic re-entrant honeycombs constructed by adjusting the geometric parameters of a core unit cell are proposed, and their deformation modes and energy absorption characteristics with different impact speeds are systematically investigated. The novel graded design utilizes structural hierarchy on the meso-scale and functional gradient on the macro-scale. The numerical simulation models are verified by comparing the experimental results. The results show that compared with the ungraded honeycomb (URH), one of the graded honeycombs (GRHs), named GRH1, can greatly improve the specific energy absorption by 36.4%, 10.8%, and 6.00% for the quasi-static, low, and high-speed impact at a strain of 0.6. At the same time, the initial peak stress of GRH1 is decreased by 43.2% and 27.1% compared with that of URH for low and high-speed impact, respectively. It could be indicated that the GRH1 was an ideal energy-absorbing structure. This work provides a new route for designing graded auxetic honeycombs with enough insight to understand the deformation mechanism of the structures, which could be used in lightweight buffer protective systems.

Energy absorption structure with negative stepped plateau force characteristics under quasi-static loads

The force-displacement curve is the key to determine the energy absorption performance. Customizing the force-displacement curve enables the design of more advanced and efficient energy absorption systems. In this paper, we introduce a negative stepped plateau force structure (NSPFS) design by combining crooked plate units with curved and straight combined cross-section (CSCC) units. First, the NSPFS is fabricated by using additive manufacturing technology, and a compression experiment is conducted to validate the design methodology. Then, a finite element model is developed and compared with the experimental results to verify its effectiveness. The peak force (PF) and mean crushing force (MCF) of the crooked plate unit are primarily controlled by wall thickness t1 and initial angle θ1. When θ1 = 1.146° and t1 = 1.0 mm of crooked plate unit, the lowest point of the plateau phase decreases by 84 % compared to the PF, and the ratio of PF to MCF is 4.9. When the PF of the crooked plate unit is greater than the PF of the CSCC unit, the structure has the characteristics of negative stepped plateau force. More phase plateau forces can be obtained when multiple NSPFS are compressed in series. When multiple NSPFS units are compressed in parallel, multi-phase continuous negative stepped plateau force can be achieved. Therefore, NSPFS allows for the customization of complex force-displacement curves through series and parallel design.

Similarity design method and multi-objective optimization of train energy-absorbing tube velocity distortion under axial impact

Thin-walled tubes are commonly used as crucial structures for energy absorption. It is an efficient and convenient research method to establish a small-scale model of the energy-absorbing thin-walled tube for experiments. However, due to the inevitable difference between the design velocity of the test and the actual velocity of the test, it cannot meet the traditional similarity theory. Because of this limitation, this article constructs a similarity design method for the velocity distortion of the multi-cell energy-absorbing tube at the front end of the train under axial impact. Firstly, according to the motion equation of the train system, the design criterion of the similar model under the velocity distortion is derived. Then, the collision mass correction factor is derived based on the elastic-plastic structural energy equation, aiming at the error of the collision peak force and the error of the collision time, the correction factor of the wall thickness of the energy absorbing tube is obtained based on the simulation analysis results. Finally, it is verified that the velocity distortion similarity model can accurately predict the dynamic response of the prototype, and reveals the influence of the mass and wall thickness correction factors on the error.

Research on the Energy-Absorbing and Cushioning Performance of a New Half-Bowl Ball Rubber Body in Tunnel Support

As coal mine underground operating conditions are harsh, strengthening and optimizing the support structure is conducive to the safety of mining work and personnel. Currently, underground support devices face problems such as poor environmental adaptability and unbalanced performance of shockproof and energy absorption. At the same time, the energy absorption mechanism and impact dynamic analysis of the support structure are still imperfect. This paper proposes a simple and effective bionic half-bowl spherical rubber energy-absorbing structure based on the actual production needs of coal mines, with energy-absorbing rubber as the main structural interlayer. A combination of experimental testing and simulation was used to reveal the dynamic response and mechanism of simulated energy absorption of a half-bowl-shaped rubber layer under different working conditions. Abaqus software was used to simulate and analyze the dynamic response of the half-bowl spherical rubber structure under the impact condition, and the simulation data were compared with the experimental results. In addition, the relationship between energy absorption and stress at the rubber structure and the base plate under different impact velocities was investigated. The results show that the simulated and experimental results of the rubber structure have almost the same pressure vs. time trend within 0.1 s at an impact velocity of 64 m/s, and there is no significant wear on the rubber surface after impact. Due to the energy-absorbing effect of the rubber structure, the maximum stress of the bottom member plate-2 of the mechanism is lower than 9 × 104 N. The maximum amount of compression of the half-bowl ball is 37.56 mm at an impact velocity of 64 m/s. The maximum amount of compression of the half-bowl ball is 37.56 mm.

Experimental and numerical study on CuO/ZnO-modified aramid fabric for ballistic and UV radiation protection

Aramid fabrics are widely used in bulletproof armor because of their excellent mechanical properties. Previous studies have shown that ultraviolet radiation has a negative effect on the mechanical properties of aramid yarn, so improving the mechanical properties and impact resistance of aramid fabrics under ultraviolet radiation has become a research focus. In this work, aramid fabric was modified with CuO and ZnO particles to improve its ballistic performance under ultraviolet radiation. The ballistic impact resistance response and microscopic failure mechanisms of aramid fabrics under ultraviolet radiation were analyzed in detail. Under ultraviolet radiation, the ballistic limit velocity (vbl) of the CuO/ZnO-modified aramid fabric was 185.1 % greater than that of a neat fabric with a similar areal density. The vbl of the single-layer modified fabric was 45.6 % greater than that of the two-layer neat fabrics. The decrease in the ballistic performance of the aramid fabric under ultraviolet radiation was attributed to surface damage caused by the fracture of the chemical structure of the fibers, which weakened the mechanical properties of the fabric. The numerical simulation results were highly consistent with the ballistic impact test results, and the error between the numerical simulation and experimental results was within 10 %. The effects of changes in the mechanical parameters of the fabrics on the protection mechanism and energy absorption structure during ballistic impact were investigated. The energy dissipation of the modified fabric was at least 147.7 % greater than that of the neat fabric, further explaining the significant improvement in the ballistic performance of CuO/ZnO-modified fabrics under ultraviolet radiation.

Crashworthiness and optimization design of additive manufacturing double gradient lattice enhanced thin-walled tubes under dynamic impact loading

It is of paramount importance to ensure the protection of both infrastructure and personnel in scenarios characterized by a high strain rate dynamic impact. In order to develop lighter weight and higher crashworthiness energy-absorbing structures, this paper incorporates the bionic design of lattice reinforced thin-walled tube structures in the form of double gradient, as a means of achieving the aforementioned objectives. Material mechanical properties and the designed structures at high strain rate were researched using Split Hopkinson Pressure Bar (SHPB) experiment. The effects of gradient form and gradient parameters on the deformation pattern and crashworthiness of lattice enhanced thin-walled tubes are researched by means of the validated finite element model and the experimentally fitted Johnson-Cook material model. The results indicate that the specific energy absorption of the double gradient lattice enhanced thin-walled tube (T3L3) is increased by 36.19 % and the peak crush force is reduced by 21.19 % compared to the lattice enhanced thin-walled tube without gradient. Finally, the multi-objective optimization analysis of the T3L3 with the objective of achieving the maximum SEA and minimum PCF is carried out by Response Surface Methodology (RSM) and Non-dominated Sorting Genetic Algorithm-II (NSGA-II) to find the Pareto optimal solution set. Double-gradient bionic structure offers a new idea for designing energy-absorbing structures under high-speed impact conditions.

A machine learning-based crashworthiness optimization for a novel pine cone-inspired multi-cell tubes under bending

Bionic tubes are of interest in vehicle engineering due to their superior crashworthiness potential. This study proposes a crashworthiness response investigation and machine learning-based multi-objective optimization of pine cone-inspired muti-celled tubes (PCMTs). The base computer PCMT model was correlated using existing experiments, followed by a dynamic response evaluation of different PCMT geometrical and thickness configurations to assess their structural performance. Surrogate models of these PCMTs were then constructed using machine learning algorithms, and their main and interaction effects were analyzed. A non-dominated sorting genetic algorithm II (NSGA-II) approach was employed to perform a multi-objective optimization. The results demonstrate that thickness change had more effect on the initial peak force (IPF) and the mean crushing force (MCF) than the specific energy absorption (SEA). Besides, due to the coupling effect, IPF, MCF and SEA of the optimal design solution of the PCMTs could reach a 36.82 %, 61.66 % and 72.95 % increase than the sum case, suggesting that embedding inner tubes could significantly increase energy absorption with a relative minor IPF increase. Moreover, the MCF and SEA of optimal design gave an average difference of 18.01 % and 5.91 % from the original tubes. PCMTs, therefore, could be used as an ideal energy absorption structure in the vehicle body structures.

Effect of Extrusion Ratio on Mechanical Behavior and Microstructure Evolution of 7003 Aluminum Alloy at High-Speed Impact.

The extrusion ratio (ER) is one of the most important factors affecting the service performance of aluminum profiles. In this study, the influence of ER on the mechanical behavior and microstructure evolution of 7003 aluminum alloy at high-speed impact with strain rates ranging from 700 s-1 to 1100 s-1 was investigated. The studied alloy with an ER of 56 formed coarse grain rings during the heat treatment. The microstructure of the alloys with ERs of 20 and 9 is relatively uniform. The results indicate that under high-speed impact, the mechanical response behavior of the 7003-T6 alloy with different ERs is different. For the alloy with an ER of 56, strain hardening is the main mechanism of plastic deformation. In contrast, a flow stress reduction occurs at middle deformation stage for the ones with ERs of 20 and 9 due to concentrated deformation, which is more significant in the alloy with an ER of 20. Under high-speed impact, the alloy with an ER of 56 undergoes uneven plastic deformation due to the presence of coarse grain rings. The deformation is mainly borne by the region of coarse grains near the edge, and the closer to the center, the smaller the deformation. The deformation of the alloys with ERs of 20 and 9 is relatively uniform, but exhibits localized concentrated deformation in the area near the edge. The significant plastic deformation within deformation band causes a local temperature rise, resulting in a slight decrease in flow stress after the peak. These results can provide reliable data support for the application of 7003 aluminum alloy in the vehicle body crash energy absorption structure.

Multi-Objective Optimization of Crashworthiness of Shrink Tube Energy Absorption Structure

By means of material testing, truck testing and numerical simulation, the structural parameters of the shrink tube anti-climb device for high-speed trains were determined. The effects of cone angle, tube thickness, friction coefficient and axial length of the friction cone on the crashworthiness of the shrink tube were studied, and the main causes were analyzed. Using cone angle and tube wall thickness as input variables, and peak crush force, mean crash force and specific energy absorption as crashworthiness indexes, a proxy model was constructed using a radial basis function. The global response surface methodology was adopted to optimize the design of the shrink tube’s structural parameters. The results showed that the crashworthiness of the shrink tube was positively correlated with the cone angle, the thickness of the shrink tube and the friction coefficient, and the influence decreased successively, while the influence was negatively correlated with the axial length of the friction cone, which had the least influence. Through the optimized design, the peak force of the shrink tube increased by only 5.41%, while the specific energy absorption increased by 31.03%. Additionally, the mean force was closer to the technical requirements of 600 kN, and the crashworthiness was optimized.

Design, simulation and experiment study of a snap-fit spatial self-locking system for energy absorption

Due to the strong destructiveness and poor predictability of the impact loading, energy absorption structures are easy to cause secondary damage in emergency situations. The proposed self-locking system for energy absorption can effectively solve this problem, but also can realize fast installation, disassembly and free editing. In this paper, a new snap-fit spatial self-locking energy absorption system is designed according to the self-locking idea of mortise and tenon structure. Firstly, the effects of concentrated loading, uniform distributed loading and friction properties on the self-locking characteristics under nine different spatial directions are studied by finite element simulation. Then, the crushing mechanism is revealed by impact experiment, and the performance and engineering adaptability of the existing self-locking energy absorption systems are compared. Finally, the design criteria for the system is derived. The results show that the system will not fly away under the impact loading in any spatial direction, and has good self-locking characteristics, while the friction properties have little effect on the self-locking characteristics of the system. In addition, under the uniform distributed loading, the deformation mode is the most regular in the direction 3, and the specific energy absorption in the direction 9 is as high as 7.07 J/g. Furthermore, when the total number of the structural unit in the self-locking energy absorption system is not less than twelve, the total energy absorption is linear with the number of layers, width and total number of the structural unit. Consequently, this study provides a new research idea for the design and feasibility of the self-locking energy absorption system.

A filling lattice with actively controlled size/shape for energy absorption

This study unveils a groundbreaking development: the chain lattice structure (CLS), a unique lattice with the capability to actively adjust its size and shape for filling diverse thin-walled structures, thereby enhancing their energy absorption characteristics. Traditional lattice structures, known for excellent energy absorption, are constrained by fixed sizes and shapes post-fabrication, limiting their adaptability to various energy-absorbing structures. The CLS introduces a revolutionary lattice structure dynamically modifying dimensions and shape. Employing selective laser sintering (SLS), we craft CLS prototypes using nylon 11 material, followed by rigorous quasi-static compression experiments. The congruence between experimental and simulation analyses validates our model's accuracy. CLS actively adjusts within varying cross-sectional thin-walled square tubes, demonstrating substantial improvements in energy absorption and compression stability compared to empty tubes (ETs). Additionally, CLS adapts to diverse cross-sectional shapes, including circular, hexagonal, and triangular tubes. Comparative assessments reveal significant enhancements in energy absorption and compression stability for CLS-filled tubes. Moreover, the pre-deformed CLS model was filled with different shapes of front rails, and its axial crashworthiness and deformation pattern stability were significantly improved compared with the unfilled front rails. In summary, CLS's flexibility in adjusting to thin-walled structures of varying dimensions and shapes holds immense promise for enhancing their performance across a wide range of applications.

High energy absorption design of porous metals using deep learning

Due to its remarkable energy absorption properties, porous metals have widespread applications in engineering. However, the high randomness of pore morphology greatly hinders the effective design and analysis of high energy absorption structures. To address this challenge, this paper first introduces a deep learning-based framework for high energy absorption-oriented design of random porous metals structures. The framework comprises two steps: (i) a generator powered by Wasserstein deep convolutional generative adversarial network is developed to swiftly generate a vast design space (∼one million samples) of porous metals with real random pore morphology. (ii) an inverse search strategy based on convolutional neural network is applied to quickly pick out the optimal structure with the best energy absorption from the design space. Results show that the optimal energy absorption is about 17.71 % higher than the maximum value of initial structures from CT scan. Additionally, a 575-fold increase in computational efficiency is achieved compared to the traversal search using finite element method. Subsequently, the deformation process of the optimal structure is analyzed focusing on the pore morphology and compression performance, showing that random porous metals with uniformly sized pores are capable of withstanding higher stress under the same strain and exhibit no yield band during compression. Inspired by this, a structural homogenization method is introduced and validated to create porous metal structure with stable microstructure evolution, extended plateau stress and high energy absorption.

Crashworthiness analysis and optimization design of special-shaped thin-walled tubes by experiments and numerical simulation

Thin-walled structures are widely used as typical high-efficiency energy-absorbing structures in crash safety protection. This paper aims to combine the characteristic of the square tube which concentrates energy dissipation through angle elements with the stable fold deformation of the circular tube, and innovatively propose a special-shaped thin-walled tube that contains both angle elements and arc elements. The failure behavior and energy absorption characteristics of the special-shaped tube were investigated by compression test and numerical simulation. The simulation results showed that the special-shaped thin-walled tubes have a significant advantage in energy absorption, and the specific energy absorption of the special-shaped tubes is 31.57% and 75.2% higher than that of the equal-mass circular and square tubes, respectively. Next, through finite element analysis, the effects of various parameters and initial imperfections on the crashworthiness of the special-shaped tubes were compared. The results indicated that adjustments to geometrical parameters significantly impact the energy absorption properties and crushing behavior of thin-walled tubes. Moreover, the tube with induced circular holes exhibited an optimal deformation mode. Further, a multi-objective optimal design of the metal special-shaped tube was carried out to obtain the best parameter configuration of the metal special-shaped tube. Finally, the special-shaped structure was extended to CFRP/AL hybrid thin-walled tubes. The failure behavior and energy absorption enhancement mechanism of the hybrid special-shaped tubes were investigated with experiments, and the absorbed energy of the hybrid tube was about 20% higher than the sum of the absorbed energy of the single constituent tubes. The effect of the CFRP lay-up pattern on the crashworthiness of the hybrid tube was investigated by numerical simulation, and it was found that the energy absorption capacity of the hybrid tube could be improved by appropriately increasing the number of layers and the proportion of axial fibers.

Design of hierarchical multi-cell double circular tubes thin-walled structures for energy absorption

This study aims to investigate the crashworthiness performance of a novel hierarchical multi-cell double circular tubes (HMDC) structure under axial impact. Various dual-tube structures of different cross-sections were designed. The effects of hierarchical order, peak number of the core column, and inner circle diameter on the structure were analyzed using Abaqus finite element analysis. The results indicate that in dual-tube structures, replacing the traditional multi-cell structure with a hierarchical multi-cell structure in the interlayer significantly improves energy absorption (EA) characteristics. With the inner circle diameter of the HMDC fixed at 20 mm, the ratio of mean crushing force (MCF) to peak crushing force at the third order increased by 70.70% and 35.68% compared to the first and second orders, respectively. Experimental results and finite element results show that the initial peak value differed by 1.47%, indicating a close match between the experimental and simulation results. The parametric study shows that the inner circle diameter and the peak number of the core column significantly affect EA. The findings of this study provide effective guidance for designing multi-cell dual circular tubes with high EA efficiency.

Effect of additively manufactured polymeric inserts on impact response of construction safety helmets

Purpose Struck-by accidents (i.e. being hit by a falling object) are a leading cause of traumatic brain injuries in the construction industry. Despite the critical role of hard hats in minimizing such injuries, their overall design has not appreciably changed in decades. Therefore, this study aims to explore the potential benefits of modifying commercially available hard hat designs by incorporating a compliant cantilever and a sacrificial, energy-absorbing structure to enhance their protective capabilities against impacts. Design/methodology/approach This study involved conducting experimental impact tests to obtain the head acceleration attenuation using hard hats with a variety of compliant cantilever lattice insert designs. These lattice inserts were additively manufactured using three polymeric materials, including polylactide (PLA), acrylonitrile butadiene styrene, high-impact polystyrene and three porosity levels. A Hybrid III head/neck assembly was fitted with each hard hat design, and experimental drop tests were conducted using a 1.8-kg steel impactor dropped from 1.83 m. The maximum acceleration and head injury criterion (HIC) values were obtained for each test. Findings Analysis of variance revealed that HIC was significantly reduced for all lattices with 56% porosity (p < 0.023) compared to the control (unmodified) hard hat. The most effective insert was found to be a PLA insert with 56% porosity, which reduced the HIC value by 38% compared to the control (unmodified) hard hat, with a statistically significant p-value of 0.018. Originality/value The data present in this study reveals that simple and inexpensive modifications can be made to existing hard hat designs to reduce injury risk from overhead impacts.

Inspiring nested modular structure for axial compression performance

Modular structures can adapt to different energy absorption scenarios by changing the assembly form. In this work, inspired by Chinese window frames, four-leaf clovers, cotton rose hibiscus, and maze, a variety of nested modular (NM) structures are proposed with aluminum square tube as base platform. The finite element model of aluminum square tube (AST) is verified through quasi-static compression experiments. Building upon the above, a hierarchical aluminum square tube (HAST) structure is further proposed for enclosing multi-module nested modular (M-NM) structures. Five nested components, namely plum octagonal nested modular structure (PONM), square fluted tube nested modular structure (SFTNM), floral layered nested modular structure (FLNM), square spiral nested modular structure (SSNM), square spiral distributed nested modular structure (SSDNM), are combined with these two platforms, thus generated ten typical NMs. These NM models exhibit two deformation modes, namely the progressive folding of multilobe flaps and the hybrid of outward expansion and progressive folding. M-PONM looks like "jackfruit" after being compressed. Furthermore, the effects of reducing nested components and employing hybrid assembly techniques are further explored. The results indicate that the proposed NM structures significantly enhance the compressive resistance and stability of AST. It is noteworthy that reducing nested components weakens the coupling effects, while hybrid assembly has the opposite effect. In summary, this work provides a series of novel NM structures, providing new ideas for the design of energy absorbing structures.

Crashworthiness of Energy Absorbing Structures Under Combined Shear-Compression Loading: Effects of Materials and Geometries

Crashworthiness of Energy Absorbing Structures Under Combined Shear-Compression Loading: Effects of Materials and Geometries