cross section crash boxes

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Figure 4.9. Dimensions of tensile test sample and welded and unwelded tensile test specimens. ............................................................................................ 72 Figure 4.10. Commercially available crash boxes of a) aluminum and b) steel. ............ 73 Figure 4.11. Compression testing of crash box without trigger mechanism and montage part. .............................................................................................. 74 Figure 4.12. Original crash box compression testing a) without and b) with corrugation section. .................................................................................... 75 Figure 4.13. Compression testing of crash box with trigger mechanism. ...................... 76 Figure 4.14. Uniaxial compression testing of empty and partially foam filled crash box with montage plates. .................................................................. 78 Figure 4.15. a) Fractovis Plus drop-weight test system, b) drawing of the designed test apparatus and c) the pictures of the test sample and the sample fixture in the drop weight test. ....................................................... 80 Figure 5.1. Elastic-plastic behavior with isotropic and kinematic hardening, l0 and l are initial and final length of the tension specimen, respectively. ................................................................................................ 82 Figure 5.2. Effective plastic stress-stain curve. ............................................................ 84 Figure 5.3. Schematic of the honeycomb structure and tension, compression and shear behavior. ..................................................................................... 85 Figure 5.4. The model of a) crash box without montage plates and b) crash box with montage plates. ................................................................................... 89 Figure 5.5. Contact algorithms used in crash box modeling a) without and b) with montage plates. ................................................................................... 90 Figure 5.6. The mesh of sampling points of RSM optimization. ................................. 99 Figure 6.1. (a) Compression stress-stain curves and (b) plateau stress vs. relative density of Al foam and. ............................................................... 101 Figure 6.2. Experimental and foam model stress-strain curves of Alulight foams. ....................................................................................................... 103 Figure 6.3. Tensile stress-strain curves of 1050H14 Al sheet material. ..................... 104 Figure 6.4. (a) Tensile stress-strain curve of the welded 1050H14 Al and (b) the picture of a fractured welded Al specimen showing the failure in the heat affected zone. .................................................................................... 105 Figure 6.5. Sequential deformation pictures of (a) Al crash box (Renault) and (b) steel crash box (Honda). ..................................................................... 106 xiv
Figure 6.6. (a) load and b) SAE vs. deformation ratio (%) curves of commercial crash boxes. .......................................................................... 106 Figure 6.7. Deformation sequence pictures of G1T3E box (empty); a) without and b) with trigger mechanism. ................................................................ 108 Figure 6.8. Load-displacement and mean load-displacement curves of G1T3E box (empty) with and without trigger mechanisms. ................................. 109 Figure 6.9. Deformation sequence pictures of fixed crash box a) without and b) with corrugation. ...................................................................................... 110 Figure 6.10. Load-displacement and mean load-displacement curves of crash boxes with and without corrugation. ........................................................ 110 Figure 6.11 Load-displacement and mean load-displacement curves of crash box with and without fixing part. ............................................................. 111 Figure 6.12. Sequential deformation photos of empty and foam filled G1 geometry crash boxes with 3 mm thickness. ............................................ 112 Figure 6.13. Sequential deformation photos of empty and foam filled G1 geometry crash boxes with 2.5 mm thickness. ......................................... 113 Figure 6.14. Sequential deformation photos of empty and foam filled G1 geometry crash boxes with 2 mm thickness. ............................................ 114 Figure 6.15. Sequential deformation photos of empty and foam filled G2 geometry crash boxes with 3 mm thickness ............................................. 115 Figure 6.16. Sequential deformation photos of empty and foam filled G2 geometry crash boxes with 2.5 mm thickness at 60 mm deformation. ............................................................................................. 116 Figure 6.17. Sequential deformation photos of foam filled crash G2 geometry boxes with 2mm thickness at 60 mm deformation. .................................. 116 Figure 6.18. Load-displacement graphs of crash box with Geometry of G1 and G2 a) 3 mm thickness, b) 2.5 mm thickness and c) 2 mm thickness. ...... 117 Figure 6.19. Mean load -displacement graphs of crash box with Geometry of G1 and G2 a) 3 mm thickness, b) 2.5 mm thickness and c) 2 mm thickness. .................................................................................................. 118 Figure 6.20. SEA vs. displacement graphs of crash box with Geometry of G1 and G2, a) 3 mm thickness, b) 2.5 mm thickness and c) 2mm thickness. .................................................................................................. 119 xv
Page 1 and 2: OPTIMIZATION OF THE AXIAL CRUSHING
Page 3 and 4: ACKNOWLEDGEMENTS My PhD quest has b
Page 5 and 6: ÖZET KAPALI HÜCRELİ ALUMİNYUM K
Page 7 and 8: CHAPTER 4 EXPERIMENTAL DETAILS ....
Page 9 and 10: CHAPTER 8 ALUMINUM CRASH BOX OPTIMI
Page 12 and 13: Figure 3.7. Simulations of the defo
Page 16 and 17: Figure 6.21. Sequential deformation
Page 18 and 19: Figure 7.20. Sequential deformation
Page 20 and 21: LIST OF TABLES Table Page Table 4.1
Page 22 and 23: Figure 1. 1. The body in white stru
Page 24 and 25: Figure 1. 4. Commercial crash boxes
Page 26 and 27: CHAPTER 2 AL CLOSED CELL FOAMS: PRO
Page 28 and 29: The processing methods and mechanic
Page 30 and 31: Figure 2. 5 The preferred particle
Page 32 and 33: Figure 2. 8. Typical cellular struc
Page 34 and 35: Figure 2. 10. Manufacturing cost of
Page 36: Figure 2. 12. Laser assisted foamed
Page 41 and 42: Figure 2.16. Shear strength, normal
Page 43 and 44: Figure 2. 19. Yield strength vs. re
Page 45 and 46: Figure 2. 21. Unit cell geometry an
Page 47 and 48: Figure 2. 24. Load-displacement cur
Page 49 and 50: Figure 2. 26. The photographs of a
Page 51 and 52: CHAPTER 3 CRUSHING BEHAVIOR OF TUBU
Page 53 and 54: Figure 3.2. Diamond deformation mod
Page 57 and 58: deformation mode transition from ax
Page 59 and 60: Figure 3.8. Energy absorption of qu
Page 61: (a) (c) Figure 3.10. Deformation mo
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(a) (b) Figure 3.13. a) Schematic o
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(a) (b) (c) Figure 3.15. a) Load-di
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Figure 3.18. The crush terminology.
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The quasi-static compression behavi
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Figure 3.22. The variation of speci
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Figure 3.24. Deformation modes of e
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Figure 3.27. SEA values of empty an
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Figure 3.29. (cont.) 3.5. Motivatio
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CHAPTER 4 EXPERIMENTAL DETAILS 4.1.
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(a) (b) Figure 4.3.Pictures of a) f
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oxes are shown in Figure 4.6. The l
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Figure 4.7. The method of trigger m
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4.4. Compression Tests of Crash Box
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4.5.2. Uniaxial Compression Testing
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Table 4.1 (Cont.) G1 T3 F2 G1T3F2 3
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Table 4.2 (Cont.) G1 T2.5 WP F2 G1T
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CHAPTER 5 SIMULATION AND OPTIMIZATI
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considered in axial and transverse
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were constrained. Since the width o
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5.4. The Crashworthiness Optimizati
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great effect on the crushing behavi
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CHAPTER 6 EXPERIMENTAL RESULTS 6.1.
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Figure 6.3.Tensile stress-strain cu
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(a) (b) Figure 6.5. Sequential defo
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plate (Figure 6(b)). The trigger is
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(a) (b) Figure 6.9. Deformation seq
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Figure 6.12. Sequential deformation
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Figure 6.18. (cont.) (c) (a) (b) Fi
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Figure 6.20.(cont.). (b) (c) 6.5.4.
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Figure 6.21.(cont.) (b) (c) 122
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Figure 6.22.(cont.) (c) Figure 6.23
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Figure 6.24.(Cont.) (b) (c) (a) Fig
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Figure 6.26.(cont.) (b) (c) 6.6. Dy
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Figure 6.27. (cont.) (b) (c) 130
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CHAPTER 7 MODELING RESULTS OF FOAM,
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experimental tensile stress-strain
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significant effect of weld seem ope
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Figure 7.7. Deformation photo of fi
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Figure 7.11. Deformation photos of
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(a) (b) (c) Figure 7.14. Load-displ
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7.4. Simulation of Empty and Partia
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Figure 7.16. (cont.) (c) (a) Figure
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(a) (b) Figure 7.18. Sequential def
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Figure 7.19. (cont.) (b) (c) 150
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Figure 7.20. (cont.) (c) (a) Figure
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(a) (b) Figure 7.26. Experimental a
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The constructed response surface of
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Table 8.1. R 2 , Radj 2 and RMSE va
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(a) (b) Figure 8.7. Response surfac
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an empty tube wall thickness higher
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where, K is a dimensionless constan
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The dynamic simulation and analytic
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Figure 9.4. (cont.) (c) (d) Figure
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Figure 9.6. (cont.) (c) (d) (a) Fig
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Equation 9.7 can also be rewritten
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(a) (b) Figure 9.10. Energy-absorbi
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Figure 9.11. (cont.) (d) The variat
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foam filling were evaluated. The re
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13. The interaction between foam fi
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Arora, J. S.,2004,Introduction to O
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Dannemann, K. A. and Lankford, J.,
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Hall, I. W., Guden, M. and Yu, C. J
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Kim, D-K. and Lee, S., 1999, Impact
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Mamalis, A. G., Manolakos, D. E., I
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Pugsley, A. G. and Macaulay, M., 19
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T. Miyoshi, M. Itoh S. Akiyama A. K
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Zhao, H., Elnasri, I. and Girard, Y
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