Modeling and optimization of foam-filled thin-walled columns for crashworthiness designs

• Published in: Finite elements in analysis and design Vol. 46; no. 9; pp. 698 - 709
• Main Authors: Bi, Jing, Fang, Hongbing, Wang, Qian, Ren, Xuchun
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 01.09.2010; Elsevier
• Subjects: Aluminum foam; Crashworthiness; Crushing; Design engineering; Exact sciences and technology; Finite element; Foams; Fundamental areas of phenomenology (including applications); Inelasticity (thermoplasticity, viscoplasticity...); Mathematical analysis; Mathematical models; Mathematics; Methods of scientific computing (including symbolic computation, algebraic computation); Numerical analysis. Scientific computation; Optimization; Physics; Response surface methodology; Sciences and techniques of general use; Solid mechanics; Structural and continuum mechanics; Thin walled; Thin-walled column; Tubes; Thin-walled column; Response surface methodology; Aluminum foam; Crashworthiness; Optimization; Finite element; High strain; Tube; Constraint; Porous material; Modeling; Finite element method; Inelasticity; Mechanism synthesis; Energy dissipation; Column; Metal foam; Response surface; Safety; Cell structure; Aluminium; Automobile industry; Thin walled beam; Energy absorption; Crush; Mechanical shock
• ISSN: 0168-874X; 1872-6925
• DOI: 10.1016/j.finel.2010.03.008

Thin-walled columns play an important role on passenger safety in vehicular collisions for their progressive deformation patterns and large energy absorptions. A thin-walled column with a large specific energy, i.e., the ratio of energy absorption to its mass, is often desirable to the automotive industry, because such designs could enhance safety and reduce manufacturing cost. Due to the complexity of crash mechanism, obtaining such designs has been a challenge to the trial-and-error approach using physical prototype testing. To this end, combining finite element simulations with optimization methodologies has become the viable means to meet the challenge. In this paper, single- and triple-cell hexagonal columns filled with aluminum foams were optimized for maximum specific energy with simultaneous consideration of section geometry, tube thickness, and foam density. The effects of crushing forces on column designs were analyzed by comparing optimum solutions with and without constraints on the mean crushing forces. The interaction effects between the tube and foam of composite columns and the relative advantages of single- and triple-cell structures were investigated and discussed.