A novel efficient energy absorber with free inversion of a metal foam-filled circular tube

In this paper, a novel efficient energy absorber with free inversion of a metal foam-filled circular tube(MFFCT) is designed, and the axial compressive behavior of the MFFCT under free inversion is studied analytically and numerically. The theoretical analysis reveals that the energy is mainly dissipated through the radial bending of the metal circular tube, the circumferential expansion of the metal circular tube, and the metal filled-foam compression. The principle of energy conservation is used to derive the theoretical formula for the minimum compressive force of the MFFCT over free inversion under axial loading. Furthermore, the free inversion deformation characteristics of the MFFCT are analyzed numerically. The theoretical steady values are found to be in good agreement with the results of the finite element(FE) analysis. The effects of the average diameter of the metal tube, the wall thickness of the metal tube, and the filled-foam strength on the free inversion deformation of the MFFCT are considered. It is observed that in the steady deformation stage, the load-carrying and energy-absorbing capacities of the MFFCT increase with the increase in the average diameter of the metal tube, the wall thickness of the metal tube, or the filled-foam strength. The specific energy absorption(SEA) of free inversion of the MFFCT is significantly higher than that of the metal tube alone.

Mechanical properties and energy absorption properties of aluminum foam-filled square tubes

Longitudinal and transverse mechanical properties and energy absorption properties of foam-filled square tubes under quasi-static loading conditions were studied.The foam-filled thin-walled square tube was fabricated with aluminum tube as its shell and closed-cell Al-Mg alloy foam as its core.The results indicated that the plateau region of the load-displacement curve exhibited a marked fluctuant serration which was clearly related to the formation of folds.The longitudinal deforming mode of foam-filled square tube was the same as that of the empty tube,but the fold number of foam-filled square tube was more than that of the empty tube.The longitudinal compression load and energy absorption value of foam-filled square tube were higher than the sum of that of aluminum foam (alone) and empty tube (alone) due to the interaction between tube and filler.In transverse direction,the compression load and energy absorption ability of foam-filled square tubes were significantly lower than those in longitudinal direction.

Microstructure Distribution Characteristics of High-Strength Aluminum Alloy Thin-Walled Tubes during Multi-Passes Hot Power Backward Spinning Process

The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning process as it can eliminate casting defects, refine microstructure and improve the plasticity of the tube. To analyze the microstructure distribution characteristics of the tube during the spinning process, a 3D coupled thermo-mechanical FE model coupled with the microstructure evolution model of the process was established under the ABAQUS environment. The microstructure evolution characteristics and laws of the tube for the whole spinning process were analyzed. The results show that the dynamic recrystallization is mainly produced in the spinning deformation zone and root area of the tube. In the first pass, the dynamic recrystallization phenomenon is not obvious in the tube. With the pass increasing, the trend of dynamic recrystallization volume percentage gradually increases and extends from the outer surface of the tube to the inner surface. The fine-grained area shows the states of concentration, dispersion, and re-concentration as the pass number increases. .

Analysis and Optimization of the Electrohydraulic Forming Process of Sinusoidal Corrugation Tubes

Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic forming process.In the present study,the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed.In particular,the orthogonal experimental design(OED)and central composite design(CCD)methods have been used.Through the range analysis and variance analysis of the experimental data,the influence degree of wire diameter(WD)and discharge energy(DE)on the forming quality was determined.Multiple regression analysis was performed using the response surface methodology.A prediction model for the attaching-die state coefficient was established accordingly.The following optimal arrangement of parameters was obtained(WD=0.759 mm,DE=2.926 kJ).The attaching-die state coefficient reached the peak value of 0.001.Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED.The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.

Sequential multi-objective optimization of thin-walled aluminum alloy tube bending under various uncertainties

Combining the design of experiments(DOE)and three-dimensional finite element(3D-FE)method,a sequential multiobjectiveoptimization of larger diameter thin-walled(LDTW)Al-alloy tube bending under uncertainties was proposed andimplemented based on the deterministic design results.Via the fractional factorial design,the significant noise factors are obtained,viz,variations of tube properties,fluctuations of tube geometries and friction.Using the virtual Taguchi’s DOE of inner and outerarrays,considering three major defects,the robust optimization of LDTW Al-alloy tube bending is achieved and validated.For thebending tools,the robust design of mandrel diameter was conducted under the fluctuations of tube properties,friction and tubegeometry.For the processing parameters,considering the variations of friction,material properties and manufacture deviation ofmandrel,the robust design of mandrel extension length and boosting ratio is realized.

Significance-based optimization of processing parameters for thin-walled aluminum alloy tube NC bending with small bending radius

Thin-walled aluminum alloy tube numerical control （NC） bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element （FE） simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d50 mm×1 mm×75 mm and d70 mm×1.5 mm×105 mm （initial tube outside diameter D0 × initial tube wall thickness t0 × bending radius R）, and qualified tubes are produced.

Efficient energy absorption of functionally-graded metallic foam-filled tubes under impact loading

The deformation behavior and crashworthiness of functionally-graded foam-filled tubes(FGFTs)under drop-weight impact loading were investigated.Closed cell aluminum,A356 alloy and zinc foams fabricated by the liquid state processing were used as axial grading fillers for the manufacture of single-layer and multilayer structures with different configurations.The results indicate that the deformation of multilayer foam filled tubes initiates from the low-strength components,and then propagates in the high-strength components through the gradual increment of stress.The use of more A356 alloy and aluminum foam layers provides greater specific energy absorption(SEA)for the graded structures,whereas the high-strength zinc foam has no positive effect on the crash performance.The progressive collapse of graded structures consisting of the aluminum and A356 alloy foams occurs in a symmetric mode under quasi-static and drop-weight impact conditions.However,the zinc foam causes a combination of symmetric and extension modes as well as greater localized deformation under dynamic loading and greater local rupture in quasi-static loading condition.The Al−A356 foam-filled tubes with a combination of the highest SEA(10 J/g)and the lowest initial peak stress(σmax of 10.2 MPa)are considered as the best lightweight crashworthy structures.

Study on corrosion resistance of the BTESPT silane cooperating with rare earth cerium on the surface of aluminum-tube

Bis-3-(triethoxysilyl)propyltetrasulfide(BTESPT) silane-rare earth cerium composite coatings on aluminum-tube were prepared at 60 °C by immersion method.The performance of composite coatings to protect the aluminum-tube against corrosion was investigated with potentiodynamic polarization curves,electrochemical impedance spectroscopy(EIS),and salt spray test(SST).The results of potentiodynamic polarization curves and EIS indicated that the self-corrosion current decreased by two orders of magnitude and the i...

Effects of process parameters on numerical control bending process for large diameter thin-walled aluminum alloy tubes

Numerical control(NC) bending experiments with different process parameters were carried out for 5052O aluminum alloy tubes with outer diameter of 70 mm, wall thickness of 1.5 mm, and centerline bending radius of 105 mm. And the effects of process parameters on tube wall thinning and cross section distortion were investigated. Meanwhile, acceptable bending of the 5052O aluminum tubes was accomplished based on the above experiments. The results show that the effects of process parameters on bending process for large diameter thin-walled aluminum alloy tubes are similar to those for small diameter thin-walled tubes, but the forming quality of the large diameter thin-walled aluminum alloy tubes is much more sensitive to the process parameters and thus it is more difficult to form.

Non-steady FE analysis on porthole dies extrusion of aluminum harmonica-shaped tube

According to the rigid-viscoplasticity finite element method,the porthole die extrusion process of an aluminum harmonica-shaped tube was successfully simulated based on software Deform-3D. The distribution of stress field,effective strain field,velocity field and temperature field during the extrusion process were discussed and the metal flow in welding extrusion was analyzed. The simulation results show that the material flow velocities in the bearing exit are non-uniform with the originally designed die and the forepart of the profile is not neat or even. Aiming at solving this problem,the modification method of die structure was improved. The result shows that the uniform material flow velocities in the die exit and a perfect extruded are obtained by modification bearing length.

Experimental investigation and numerical simulation of large-sized aluminum tube extrusion forming

Large-sized aluminum tube has big section effect, aspect ratio and thin thickness, so that the extrusion technology is complex and the large specific pressure is generated in extrusion cavity. The temperature variation and velocity effect is difficult to control. The extrusion forming of large-sized aluminum tube was researched and simulated. Three-dimensional thermo-mechanical coupled finite element model was constructed and appropriate boundary conditions were given out. The results show that large-sized aluminum tube can be formed by isothermal extrusion through controlling the extrusion velocity and founding the relationship between extrusion velocity and extrusion temperature.

热处理对2219铝合金薄壁旋压管组织与性能的影响

本文对2219铝合金薄壁旋压管进行了退火、固溶及时效热处理,研究了热处理工艺对微观组织、拉伸性能和液压胀形性能的影响。结果表明:2219铝合金旋压管在400℃以下退火时以回复为主,温度高于450℃时发生再结晶。随退火温度升高,基体组织逐渐由形变组织向再结晶组织转变。固溶处理时随固溶时间延长,再结晶程度逐渐增加,位错密度降低。经退火和固溶处理后,管材的硬化率和延伸率显著提高,抗拉强度随着退火和固溶温度升高而逐渐增大,固溶处理后抗拉强度达到340 MPa,延伸率提高到25%。时效处理后管材的抗拉强度进一步提高到435.2 MPa。管材液压胀形极限随热处理温度升高而升高,固溶态2219铝合金旋压管具有较好的液压胀形能力,适合进行液压成形。

Simulation of temperature field and metal flow during continuous semisolid extending extrusion process of 6201 alloy tube

A continuous semisolid extending extrusion （CSEP） method was proposed. Temperature field and metal flow during continuous semisolid extending extrusion process of 6201 alloy tube were studied. During the process, the temperature in the roll-shoe cavity decreases gradually, and the isothermal lines of the alloy deviate from the shoe side to the work roll side in the roll–shoe gap. Metal flow velocity decreases gradually from the surface of the work roll to the surface of the shoe. In the extrusion mould, alloy temperature decreases gradually from the entrance to the exit and from the center to the sidewall of the mould. The extending cavity is radially filled with the alloy. The flow lines in the tube corresponding to the centers of the splitflow orifices and the welding gaps are dense, and the corresponding harness values are high; there are 8 transitional bands between them. In order to prepare 6201 alloy tubes with good surface quality, the pouring temperature from 750 ℃ to 780 ℃ was suggested.

多壁管增强泡沫铝结构动态响应及吸能性能研究

为了提高泡沫铝吸能性能,该文将多壁管及泡沫铝材料相结合,提出了一种多壁管增强泡沫铝结构.通过Hopkinson压杆试验以及有限元分析软件ABAQUS/Explicit,研究了泡沫铝、多壁管及其增强泡沫铝的动态压溃特性.对比分析了泡沫铝复合多壁管前后的变形模式、吸能性能,并讨论了多壁管增强泡沫铝的应变率效应以及应变率对多壁管增强泡沫铝耦合增强作用的影响.研究表明,有限元仿真能够较好地模拟试验结果.测试结果表明所采用的泡沫铝应变率效应不明显,而多壁管及多壁管增强泡沫铝应变率效应较为明显,在高应变率下其能量吸收可进一步提升.在动态冲击条件下,多壁管增强泡沫铝峰值力相比单一多壁管或泡沫有明显的耦合增强,其能量吸收相比单一多壁管及泡沫铝能量吸收之和提升10.34%.通过研究多壁管增强泡沫铝的动态压溃特性,可为承载吸能构件的应用提供依据和参考.

铝/水两相自点火实验和理论研究

针对铝/水冲压发动机水蒸气氛围金属燃料点火燃烧机理不明、基础燃烧实验数据缺乏等问题,基于可视化高压激波管实验平台开展了铝/水两相自点火实验和理论研究,从发光强度及火焰图像、自点火温度和点火延迟3种角度表征了铝粉的温度效应、压力效应和尺度效应,揭示了铝/水和铝/氧点火机理的差异性,构建了铝/水自点火温度预示模型。实验结果表明:铝/水点火模式为小粒径颗粒优先着火,再引燃大粒径铝颗粒着火;临界自点火温度与铝颗粒粒径呈现反向依赖关系;点火延迟时间与温度关系符合Arrhenius关系式,颗粒越大,点火延迟的温度敏感性越高;纳米级铝粉点火延迟呈现较强的压力依赖行为,高压下火焰区域更为集中,铝粉颗粒之间竞争氧化剂更加剧烈;铝粉点火延迟的尺度效应明显,1500K下50.0μm粒径铝粉点火延迟时间约为100nm粒径铝粉的30倍。研究结果表明,铝/水自点火特性优于铝/氧,所构建的铝/水模型对微米颗粒自点火温度的预测值与文献实验值偏差较小。该研究的基础燃烧数据和点火机制理论分析可为铝/水冲压发动机的燃烧组织优化及燃烧室结构设计提供理论依据,为铝/水点火机理和模型的发展提供研究思路。

CFRP-铝合金复合管高强混凝土短柱轴压性能研究

为研究CFRP-铝合金复合管混凝土构件的轴压性能,进行了12根短柱试件的轴向压缩试验,主要研究参数为CFRP层数。试验结果表明:复合管混凝土试件出现了多处外凸鼓曲以及对应位置混凝土被压溃的破坏形态,而空复合管试件发生了局部内凹屈曲破坏;试件轴压承载力随CFRP层数的增加而增大,且复合管混凝土试件的承载力提高幅度高于相应的空复合管试件的提高幅度。对各部分的承载力贡献比例进行分析,发现复合管混凝土试件中混凝土的承载力贡献比例超过70%,且承载力贡献度随CFRP层数的增加而提高。提出了CFRP-铝合金复合管混凝土构件的轴压承载力计算公式。

铝合金三通管铸造工艺设计及优化

文中针对铝合金三通管铸件的结构进行了工艺分析,结合铝合金材质特点确定了该铸件的铸造工艺方案和工艺参数,设计计算了三通管铸件的浇冒口尺寸,通过对设计工艺进行数值模拟分析铸件的充型和凝固过程,通过流场发现采用底注开放式浇注系统可以最大程度地保证充型的平稳性;通过凝固场发现在铸件热节位置设计保温冒口和冷铁可以有效消除缩孔和疏松缺陷,试制铸件满足探伤和无损检测技术要求,获得了优化的工艺方案。

工艺参数对铸态7075铝合金管旋压成形强度的影响

工艺参数对铸态7075铝合金管旋压成形强度的影响至关重要。本文以抗拉强度与屈服强度作为成形质量指标,系统地分析了压下量、预热温度、进给比和摩擦条件等工艺参数对铸筒旋压件强度的影响。结果表明:随着压下量的增加,管的抗拉强度与屈服强度增加;随着预热温度的上升或者进给比的增加,管的抗拉强度与屈服强度先增加后减少;随着摩擦系数的增加,管的抗拉强度与屈服强度先增加后减少,但变化不明显。

一种组合式二级缓冲吸能装置的吸能特性研究

基于胀管和泡沫铝的缓冲吸能特性,以能量吸收值为设计目标,提出了一种新型二级缓冲吸能装置设计方法,并通过准静态压缩试验和落锤冲击试验验证了该方法的有效性。试验结果表明:该二级装置可实现预期的多级梯度应力平台。建立了二级缓冲吸能装置的有限元模型,通过仿真分析其在不同冲击工况下的动态响应和能量变化特征,该装置泡沫铝和胀管部分吸能占比可达80%,且更换主要耗能部分后其余构件可实现重复使用,并针对其失效模式提出优化方法,有效增加耗能材料的利用率和装置的整体稳定性。

空心管型泡沫铝吸声性能的数值模拟分析

为了提高多孔泡沫铝材料的吸声性能,将泡沫铝加工成空心管型结构。首先,利用声学阻抗管测试系统获取吸声系数;其次,基于JCA声学模型,采用COMSOL软件对空心管型泡沫铝进行仿真模拟以获取吸声系数,将吸声系数仿真结果与试验结果进行对比,验证仿真模型的可靠性;最后,通过声压云图和能量耗散云图对空心管型泡沫铝内部声场进行分析,并进一步通过数值模拟探究空心管参数对吸声性能的影响规律。研究结果表明:该空心管型结构属于共振式吸声结构;当声波的频率和结构中固有频率相同时,声波激励结构振动的振幅最大,导致大量的声能被消耗,从而起到吸声的作用;对于空心管型泡沫铝结构,可以通过增大空心管的半径、增加空心管的数量来提高吸声系数;在1000~6300 Hz的频率范围内,背后添加空腔的空心管型泡沫铝结构的平均吸声系数相较于背后添加空腔的均质型泡沫铝结构的平均吸声系数提高了26%。