Design of crashworthy attenuator structures as a part of vehicle safetyagainst impact:Application of waste aluminum can-based material

The impact attenuator is an essential system in both race cars and urban vehicles.The structure of animpact attenuator serves as a safety barrier between the impacted surface and the driver in an accident.Attenuator materials tend to have a high price;thus,alternative materials were explored in the currentwork,i.e.,used cans from food and beverage containers.The study deployed a nonlinear finite elementalgorithm to calculate a series of impacts on the attenuator structures.The thickness of the cans andvelocity of the impact were considered as the main parameters.Analysis results concluded that the at-tenuator’s average energy was 16000 J for a can thickness of 1 mm.This value is more than two times the0.5 mm thick used cans.The attenuator’s new design was then matched with an attenuator regulation,and the results surpassed the standard value of 7350 J.

Crashworthiness Design and Multi-Objective Optimization of Bionic Thin-Walled Hybrid Tube Structures

Thin-walled structures are widely used in cars due to their lightweight construction and energy-absorbing properties.However,issues such as high initial stress and lowenergy-absorbing efficiency arise.This study proposes a novel energy-absorbing structure inwhich a straight tube is combinedwith a conical tube and a bamboo-inspired bulkhead structure is introduced.This configuration allows the conical tube to flip outward first and then fold together with the straight tube.This deformation mode absorbs more energy and less peak force than the conical tube sinking and flipping inward.Through finite element numerical simulation,the specific energy absorption capacity of the structure is increased by 26%compared to that of a regular circular cross-section tube.Finally,the impact resistance of the bionic straight tapered tube structure is further improved through multi-objective optimization,promoting the engineering application and lightweight design of hybrid cross-section tubes.

Static strength and crashworthiness analysis of a train cowcatcher at a running speed of 160 km/h

The cowcatcher is one of the unique devices at the front end of the train, which can remove obstacles on the track by crashing before the vehicle body to ensure the safety of the train. When a collision accident happens, the cowcatcher serves as the first energy-absorbing structure to dissipate and guide the collision energy. The design of the existing cowcatcher of multiple units generally focuses on the good ability to remove obstacles, while the secondary function, the crashworthiness of orderly deformation under collision, still needs further research. In this study, a finite element model of structural static load and collision analysis was established under standard EN 15227, with the cowcatcher for 160 km/h train as the prototype. Then the solution and simulation process was accomplished under the environment of ANSYS and LS-DYNA. The analysis results showed that the structural static strength of the current cowcatcher met the requirements of the standard EN 15227, and the longitudinal stiffness was evenly distributed. When removing the obstacles with low mass, the impact force was small and the structure would not produce obvious deformation;when removing the obstacles with large mass, the impact force was large and the shear fracture might occur at the connection of the cowcatcher.

Design of lightweight magnesium car body structure under crash and vibration constraints

Car body design in view of structural performance and lightweighting is a challenging task due to all the performance targets that must be satisfied such as vehicle safety and ride quality.In this paper,material replacement along with multidisciplinary design optimization strategy is proposed to develop a lightweight car body structure that satisfies the crash and vibration criteria while minimizing weight.Through finite element simulations,full frontal,offset frontal,and side crashes of a full car model are evaluated for peak acceleration,intrusion distance,and the internal energy absorbed by the structural parts.In addition,the first three fundamental natural frequencies are combined with the crash metrics to form the design constraints.The wall thicknesses of twenty-two parts are considered as the design variables.Latin Hypercube Sampling is used to sample the design space,while Radial Basis Function methodology is used to develop surrogate models for the selected crash responses at multiple sites as well as the first three fundamental natural frequencies.A nonlinear surrogate-based optimization problem is formulated for mass minimization under crash and vibration constraints.Using Sequential Quadratic Programming,the design optimization problem is solved with the results verified by finite element simulations.The performance of the optimum design with magnesium parts shows significant weight reduction and better performance compared to the baseline design.

Hybrid reinforced thermoset polymer composite in energy absorption tube application:A review

The custom of hybridization fibre composite in energy absorption tube application has gained the attention of structural crashworthiness in composite material industry. Thus, the approach of this review is to understand the effect in hybridization within metal/synthetic fibre composite, synthetic/synthetic fibre composite and nature/synthetic fibre composite as energy absorption tube, which reflects on the energy absorption characteristics and crashworthiness behaviors in previous the study. By way of instance, a wide range of methodology and particular parameter in previous study such as the effect in fibre arrangement, matrix polymer, technique of fabrication, fibre treatment(natural fibre), design in geometry/cross-section and others mechanism of hybrid fibre composite tube are highlighted which to comprehend the capability of the mechanical performance and collapsible behavior as sacrificial structure in high-performance structure applications. Moreover, in the recently studies there have been many of the research regarding structural materials as energy absorption tube has been introduced such as metal/matrix composites, new alloy metals and polymer composites which intended to evaluate the performance of these materials into circumstance in loading and impact characteristic. Therefore, this review article is trying to explore the research articles related to the effect of hybridization fibres and thermoset polymer as reinforcement for energy absorption tube research and expected would provide an information and idea which to expend the knowledge in future study of hybridization effect for energy absorption tube, moreover the development for future potential as new hybrid composite fibre materials from the natural/synthetic fibres reinforced composite material in employing of high-performance energy absorption tube application is still less discover and highlighted.

Crashworthiness design of density-graded cellular metals

Crashworthiness of cellular metals with a linear density gradient was analyzed by using cell-based finite element models and shock models. Mechanisms of energy absorption and deformation of graded cellular metals were explored by shock wave propagation analysis. Results show that a positive density gradient is a good choice for protecting the impacting object because it can meet the crashworthiness requirements of high energy absorption, stable impact resistance and low peak stress.

Crashworthiness Analysis on Alternative Square Honeycomb Structure under Axial Loading

Hexagonal metal honeycomb is widely used in energy absorption field for its special construction. However, many other metal honeycomb structures also show good energy absorption characteristics. Currently, most of the researches focus on hexagonal honeycomb, while few are performed into different honeycomb structures. Therefore, a new alternative square honeycomb is developed to expand the non-hexagonal metal honeycomb applications in the energy absorption fields with the aim of designing low mass and low volume energy absorbers. The finite element model of alternative square honeycomb is built to analyze its specific energy absorption property. As the diversity of honeycomb structure, the parameterized metal honeycomb finite element analysis program is conducted based on PCL language. That program can automatically create finite element model. Numerical results show that with the same foil thickness and cell length of metal honeycomb, the alternative square has better specific energy absorption than hexagonal honeycomb. Using response surface method, the mathematical formulas of honeycomb crashworthiness properties are obtained and optimization is done to get the maximum specific energy absorption property honeycomb. Optimal results demonstrate that to absorb same energy, alternative square honeycomb can save 10% volume of buffer structure than hexagonal honeycomb can do. This research is significant in providing technical support in the extended application of different honeycomb used as crashworthiness structures, and is absolutely essential in low volume and low mass energy absorber design.

Crushing analysis and multi-objective optimization of bitubular hexagonal columns with ribs

In order to improve the crashworthiness of thin-walled columns, the energy absorption characteristics of three columns under quasi-static axial crushing loads were analyzed through LS-DYNA. Numerical results show that the energy absorption capability of the bitubular hexagonal columns with middle to middle(MTM) ribs is the best, followed by the bitubular hexagonal columns with corner to corner(CTC) ribs and the bitubular hexagonal columns without(NOT) ribs, respectively. Then, the MTM rib was optimized by using multi-objective particle swarm optimization algorithm. Through the analysis of the Pareto front for specific energy absorption(SEA, A_(se)) and peak crushing force(PCF, F_(pc)), it is found that there is a vertex on the Pareto front. The vertex has the design parameters of t_1=1.2 mm, t_2=1.2 mm, A_(se)=11.3729 k J/kg, F_(pc)=235.8491 kN. When the PCF is in a certain size, on the left of the vertex, the point with t_2=1.2 mm has the biggest SEA, meanwhile on the right of the vertex, the point with t_1=1.2 mm has the biggest SEA. Finally, the global sensitivity analysis was conducted to investigate the effect of two design parameters. The result is obtained that both SEA and PCF for MTM are more sensitive to t_1 rather than t_2 in the design domain.

Crashworthiness Design and Multi-Objective Optimization for Bio-Inspired Hierarchical Thin-Walled Structures

Thin-walled structures have been used in many fields due to their superior mechanical properties.In this paper,two types of hierarchical multi-cell tubes,inspired by the self-similarity of Pinus sylvestris,are proposed to enhance structural energy absorption performance.The finite element models of the hierarchical structures are established to validate the crashworthiness performance under axial dynamic load.The theoreticalmodel of themean crushing force is also derived based on the simplified super folded element theory.The finite element results demonstrate that the energy absorption characteristics and deformation mode of the bionic hierarchical thin-walled tubes are further improved with the increase of hierarchical sub-structures.It can be also obtained that the energy absorption performance of corner self-similar tubes is better than edge self-similar tubes.Furthermore,multiobjective optimization of the hierarchical tubes is constructed by employing the response surface method and genetic algorithm,and the corresponding Pareto front diagram is obtained.This research provides a new idea for the crashworthiness design of thin-walled structures.

Design optimization of the S-frame to improve crashworthiness

In this paper, the S-frames, the front side rail structures of automobile, were investigated for crashworthihess. Various cross-sections including regular polygon, nonconvex polygon and multi-cell with inner stiffener sections were investigated in terms of energy absorption of S-frames. It was determined through extensive numerical simulation that a multi-celI S-frame with double vertical internal stiffeners can absorb more energy than the other configurations. Shape optimization was also carried out to improve energy absorption of the S-frame with a rectangular section. The center composite design of experiment and the sequential response surface method （SRSM） were adopted to construct the approximate design sub-problem, which was then solved by the feasible direction method. An innovative double S- frame was obtained from the optimal result. The optimum configuration of the S-frame was crushed numerically and more plastic hinges as well as shear zones were observed during the crush process. The energy absorption efficiency of the structure with the optimal configuration was improved compared to the initial configuration.

Dependence of flow strength and deformation mechanisms in common wrought and die cast magnesium alloys on orientation,strain rate and temperature

The controlling plastic deformation mechanisms(i.e.slip or twinning)and the structural crash performance of Mg alloys are strongly influenced by loading mode,texture and microstructure.This paper summarizes the main results from an experimental program to assess these effects for commercial Mg alloy extrusions(AM30 and AZ31),sheet(AZ31),and high pressure die castings(HPDC,AM50 and AM60).Uniaxial tensile and compressive tests were performed over a wide range of strain rate and temperature(i.e.0.00075–2800 s^(−1) and 100℃ to−150℃)using conventional servo-hydraulic and high-strain-rate universal test machines and a split-Hopkinson-bar(SHB)apparatus.In primarily-slip-dominant deformation,the true stress–strain curves showed approximate power-law behavior,and the effects of strain rate and temperature on yield strength could be approximately described by constitutive equations linearly dependent on the rate parameter,Tln(5.3×10^(7)/ɛ˙)where T is test temperature in Kelvin andɛ˙is strain rate in s^(−1).In primarily-twin-dominant deformation,the effects of strain rate and temperature on yield and initial flow stress were negligible or small from quasi-static to 2800 s^(−1) owing to the athermal characteristics of mechanical twinning;the effects may become more pronounced with exhaustion of twinning and increasing proportion of slip.

Investigation on structural component behaviours of double bottom arrangement under grounding accidents

Marine accidents have caused immense casualties on various parties in shipping and shipbuilding industries, including financial and structural losses. This situation makes ship accident becomes a critical subject in naval architecture and marine structures, as it needs continuous assessment and investigation to broaden insight and data of collision and grounding phenomena. The paper aims to investigate structural conditions of a ship arranged by double hull system under accidental scenario, namely ship grounding. Fundamental concept of structure-rock interaction in poweredhard grounding is adopted to design impact configuration for calculation using finite element(FE)simulation. Involved entities are defined as the structure represented by tanker vessel, and oceanic rock is deployed as the indenter in analysis. Calculation results indicate that the crashworthiness capability of structural part strengthened by longitudinal girder is higher than other selected locations on the structures against rock penetration. Localized flooding of storage oil may occur during raking damage is formed on structural part between two girders.

Crashworthiness assessment of thin-walled double bottom tanker: A variety of ship grounding incidents

This study addresses the issue of ship accidental grounding as an impact phenomenon,with the assumption that an interaction of its structure with the oceanic seabed(obstruction),idealized as rock topology,is capable of initiating a so-called hard ground scenario.This occurrence variation was considered by performing two main instances,encompassing raking and stranding,often experienced by oil/chemical tankers as thin-walled structures.In addition,a failure criterion was implemented on the structural geometry,in order to define its ultimate limit and possible damage,during interaction with the obstructions.Subsequently,the analysis results were compiled to assess structural crashworthiness as well as progressive failure of the double bottom part of the tanker,where energy criterion indicated the raking to be more destructive.Meanwhile,detailed observation of the failure sequence indicated the stranding to have successfully breached the inner bottom shell.

Design and Simulation of Single Hull Side Structure Based on Filling Sandwich

Ship collision accidents are catastrophic accidents, and as the main energy-absorbing structure, the anti-collision capacity of the side structure has an important influence on the crashworthiness of the ship. It is necessary to improve the crashworthiness of the ship by increasing energy absorption of the side structure, in such ways as adding a filling sandwich in a single hull. The aim of the present study is to discuss the crashworthiness of the side structure stressed under lateral dynamic loads through simulation with the finite element code MSC/Dytran. The collision force, the damage deformation, the critical collision speed as well as the energy absorption of a side structure improved with a filling sandwich are compared to the standard structure through numerical simulations. The results indicate that a sandwich panel structure is an advanced ship protection structure that can remarkably improve the ability of the side structure to withstand collisions; the effect of the tube-style sandwich panel structure has the best results. The outcome of this study provides a reference for the crashworthiness assessment of side structures and the crashworthiness optimization design of new side structures.

Progressive Crushing of Polymer Matrix Composite Tubular Structures: Review

The present paper reviews crushing process of fibre-reinforced polymer (FRPs) composites tubular structures. Working with anisotropic material requires consideration of specific parameter definition in order to tailor a well-engineered composite structure. These parameters include geometry design, strain rate sensitivity, material properties, laminate design, interlaminar fracture toughness and off-axis loading conditions which are reviewed in this paper to create a comprehensive data base for researchers, engineers and scientists in the field. Each of these parameters influences the structural integrity and progressive crushing behaviour. In this extensive review each of these parameters is introduced, explained and evaluated. Construction of a well-engineered composite structure and triggering mechanism to strain rate sensitivity and testing conditions followed by failure mechanisms are extensively reviewed. Furthermore, this paper has mainly focused on experimental analysis that has been carried out on different types of FRP composites in the past two decades.

Axial impact response of composite cylindrical shell

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Comparative study of honeycomb optimization using Kriging and radial basis function

Structural optimization for crashworthiness criteria is of particular significance especially at early stage of design. The comparative study of Kriging and radial basis function network （RBFN） was performed in order to improve the crashworthiness effects of honeycomb. Improving the crashworthiness characteristic of honeycomb was achieved using LS-OPT~ and domain reduction strategy. This optimization is performed on the basis of validated numerical simulation to establish the approximated model to illustrate the relationship between the responses and design variables. The results showed that Kriging meta-model is excelled in accuracy, robustness and efficiency compared to radial basis function （RBF） and crashworthiness characteristic of honeycomb is improved by 4%.

Advanced test methods of material property characterization:high strain-rate testing and experimental simulation of multiaxial stress states

Optimum utilization of the loading capability of engineering materials is an important and active contribution to protect nature's limited resources,and it is the key for economic design methods.In order to make use of the materials' resources,those must be known very well;but conventional test methods will offer only limited informational value.The range of questions raised is as wide as the application of engineering materials,and partially they are very specific.The development of huge computer powers enables numeric modelling to simulate structural behaviour in rather complex loading environments-so the real material behaviour is known under the given loading conditions.Here the art of material testing design starts.To study the material behaviour under very distinct and specific loading conditions makes it necessary to simulate different temperature ranges,loading speeds, environments etc.and mostly there doesn't exist any commonly agreed test standard.In this contribution two popular,non-standard test procedures and test systems will be discussed on the base of their application background,special design features as well as test results and typically gained information:The demand for highspeed tests up to 1000 s^(-1) of strain rate is very specific and originates primarily in the automotive industry and the answers enable CAE analysis of crashworthiness of vehicle structures under crash conditions.The information on the material behaviour under multiaxial loading conditions is a more general one.Multiaxial stress states can be reduced to an equivalent stress,which allows the evaluation of the material's constraint and criticality of stress state.Both discussed examples shall show that the open dialogue between the user and the producer of testing machines allows custom-tailored test solutions.

Laminate Tailoring of Composite Tubular Structures to Improve Crashworthiness Design at Off-Axis Loading

This paper presents experimental and numerical investigation on the parameters effecting energy absorption capability of composite tubular structures at oblique loading to improve crashworthiness performance. Various inclined angles of 5°, 10°, 20° and 30° were selected for the study of off-axis loading. The results indicate that by increasing the lateral inclination angle the mean crushing force and also energy absorption capability of all tested sections decreased. From design perspective, it is necessary to investigate the parameters effecting this phenomenon. The off-axis loading effect that causes significant reduction in energy absorption was investigated and the effected parameters were improved to increase energy absorption capability. To establish this study, 10° off-axis loading was chosen to illustrate the obtained improvement in energy absorption capability. Five cases were studied with combinations of ply-orientation and flat trimming with 45° chamfer. This method was applied to the integrated 10° off-axis loading and the final results showed significant improvement in energy absorption capability of composite absorbers. Finite element model (FEM) was developed to simulate the crushing process of axial and off-axis composite section in LS-DYNA and the results were in good agreement with the experimental data.