A three dimensional modeling method for spherical open cell aluminum foams based on spherical core stratification algorithm

Because of the complexity and irregularity of the internal structure of aluminum foam, it is difficult to establish a three-dimensional model that can accurately reflect this structure. In this study, an algorithm, named spherical core stratification algorithm, for three-dimensional modeling of spherical aluminum foam was proposed, and by using this algorithm, a three-dimensional model for sphere aluminum foam with random pores has been successfully constructed. The constructed model not only has a high similarity with the real structure of spherical open cell aluminum foam, but also can match its pore size and thickness by adjusting the size and number of holes in the random pore. In order to verify the feasibility of the modeling method, firstly, the three-dimensional model of the cylindrical spherical aluminum foam with a size of Φ35 mm × 20 mm and pore diameter of 5 mm has been generated by using the new algorithm. Secondly, taking the influence of relative density and shape function on the compressive properties of spherical open cell aluminum foams into consideration, a quasi-static constitutive model suitable for the material has been established based on the Sherwood-Frost classical compression constitutive model, which provides material parameters for quasi-static compression simulation. The comparison results show that the established constitutive equation has a good fit with the experiment, with a fitting correlation coefficient of above 0.99. Finally, the quasi-static compression simulation was carried out by ABAQUS, and the simulated nominal stress-strain curve was obtained. The simulation results indicate that the simulated stressstrain curve had the same trend with the one obtained by the quasi-static compression experiment with a small deviation.

Three dimensional modeling method of MIMICS adjacent mask spherical open cell aluminum foam-polyurethane composites based on DICOM data

The complexity and irregularity of the internal structure of aluminum foam and the particularity of the fabricating method make it difficult to establish a three-dimensional model that can accurately reflect the internal structure of aluminum foam-polyurethane composites. This study presents a method of three-dimensional reconstruction of the Materialise's Interactive Medical Image Control System (MIMICS) adjacent mask based on Digital Imaging and Communications in Medicine (DICOM) data. Firstly, spherical open cell aluminum foam-polyurethane composites with different pore sizes (5 mm, 7 mm, 9 mm) were prepared. Then the corresponding DICOM data of the spherical open cell aluminum foam-polyurethane composites were obtained by CT-scan. Based on adjacent mask, the three-dimensional simulation model of spherical open cell aluminum foam-polyurethane composites was successfully reconstructed in MIMICS. In order to verify the feasibility of this modeling method, a quasi-static compression simulation of the three-dimensional simulation model was carried out by ABAQUS, and the simulated stress-strain curves were acquired. The quasi-static compression experiments were performed on the prepared aluminum foam-polyurethane composites, and the experimental nominal stress-strain curves were obtained. The simulated nominal stress-strain curves were compared with the experimental nominal stress-strain curves. Results show that the two curves are basically the same. The feasibility and accuracy of the three-dimensional modeling method for the aluminum foam-polyurethane composites are verified.