cross section crash boxes

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foam relative density of filled boxes are tabulated in Table 8.5. It is noted in Table 8.5, higher yield strength of box material and higher plateau stresses of filler result in higher SEA values at smaller box wall thickness and foam relative densities. The highest SEA value is found in Hydro foam filled 6061T4 Al box with the optimum wall thicknesses of 2.7 mm and filler foam relative density of 0.0471. Table 8.4. R2, Radj 2 and RMSE values for RMS of partially foam filled crush box. Crush Box 1050H14- Alulight Foam 6061T4- Alulight Foam 1050H14- Hydro Foam 6061T4- Hydro Foam Response Function R 2 Radj 2 RMSE Mean Load 0.9958 0.9954 0.9912 SEA 0.9966 0.9963 0.1098 Mean Load 0.9988 0.9987 0.7193 SEA 0.9967 0.9964 0.1400 Mean Load 0.9964 0.9961 1.0290 SEA 0.9896 0.9887 0.2289 Mean Load 0.9992 0.9992 0.6379 SEA 0.9965 0.9962 0.1630 Table 8.5. Optimum thickness and relative foam density of partially Alulight and Hydro foam filled 1050H14 and 6061T4 Al boxes. Material Combination 1050H14-Alulight Foam 6061 T4-Alulight Foam 1050H14-Hydro Foam 6061 T4- Hydro Foam t (mm) 3 2.8389 3 2.7659 * 0.1114 0.0878 0.0508 0.0471 SEA(kJ/kg) 8.5648 10.1439 9.8894 11.3723 The variations of mean load and SEA values empty crush box with wall thickness are shown given in Figures 8.8(a) and (b) for 1050H14 and 6061T4 Al boxes, respectively. The maximum load value, 55 kN, as shown in these curves, corresponds to 168
an empty tube wall thickness higher than 3 mm. Even with Hydro foam filling of 1050H14 Al crash box, SEA values are lower than that of empty 1050H14 Al crash box with a tube wall thickness of 3.88 mm. However, 3.45 mm thick 6061T4 Al crash box has lower SEA values than Hydro foam filled 6061T4 Al crash box (Figure 8.8(b)). When design range is considered, the increases in SEA values with Alulight and Hydro foam filling of 1050H14 Al crash box are about 5.6% and 21.9%, respectively. The increases in SEA values with Alulight and Hydro foam filling of 6061T4 Al are 6.7% and 19.7%, respectively. (a) Figure 8.8. Mean load and SEA vs. empty box thickness; a) 1050H14 and b) 6061T4 Al crash box. (cont. on next page) 169
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OPTIMIZATION OF THE AXIAL CRUSHING
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ACKNOWLEDGEMENTS My PhD quest has b
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ÖZET KAPALI HÜCRELİ ALUMİNYUM K
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CHAPTER 4 EXPERIMENTAL DETAILS ....
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CHAPTER 8 ALUMINUM CRASH BOX OPTIMI
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Figure 3.7. Simulations of the defo
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Figure 4.9. Dimensions of tensile t
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Figure 6.21. Sequential deformation
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LIST OF TABLES Table Page Table 4.1
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Figure 1. 1. The body in white stru
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Figure 1. 4. Commercial crash boxes
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CHAPTER 2 AL CLOSED CELL FOAMS: PRO
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The processing methods and mechanic
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Figure 2. 5 The preferred particle
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Figure 2. 8. Typical cellular struc
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Figure 2. 10. Manufacturing cost of
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Figure 2. 12. Laser assisted foamed
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Figure 2.16. Shear strength, normal
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Figure 2. 19. Yield strength vs. re
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Figure 2. 21. Unit cell geometry an
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Figure 2. 24. Load-displacement cur
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Figure 2. 26. The photographs of a
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CHAPTER 3 CRUSHING BEHAVIOR OF TUBU
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Figure 3.2. Diamond deformation mod
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deformation mode transition from ax
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Figure 3.8. Energy absorption of qu
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(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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Page 138 and 139: Figure 6.18. (cont.) (c) (a) (b) Fi
Page 140 and 141: Figure 6.20.(cont.). (b) (c) 6.5.4.
Page 142 and 143: Figure 6.21.(cont.) (b) (c) 122
Page 144 and 145: Figure 6.22.(cont.) (c) Figure 6.23
Page 146 and 147: Figure 6.24.(Cont.) (b) (c) (a) Fig
Page 148 and 149: Figure 6.26.(cont.) (b) (c) 6.6. Dy
Page 150 and 151: Figure 6.27. (cont.) (b) (c) 130
Page 152 and 153: CHAPTER 7 MODELING RESULTS OF FOAM,
Page 154 and 155: experimental tensile stress-strain
Page 156 and 157: significant effect of weld seem ope
Page 158 and 159: Figure 7.7. Deformation photo of fi
Page 160 and 161: Figure 7.11. Deformation photos of
Page 162 and 163: (a) (b) (c) Figure 7.14. Load-displ
Page 164 and 165: 7.4. Simulation of Empty and Partia
Page 166 and 167: Figure 7.16. (cont.) (c) (a) Figure
Page 168 and 169: (a) (b) Figure 7.18. Sequential def
Page 170 and 171: Figure 7.19. (cont.) (b) (c) 150
Page 172 and 173: Figure 7.20. (cont.) (c) (a) Figure
Page 178: (a) (b) Figure 7.26. Experimental a
Page 182 and 183: The constructed response surface of
Page 184: Table 8.1. R 2 , Radj 2 and RMSE va
Page 187: (a) (b) Figure 8.7. Response surfac
Page 192 and 193: where, K is a dimensionless constan
Page 194 and 195: The dynamic simulation and analytic
Page 196: Figure 9.4. (cont.) (c) (d) Figure
Page 199 and 200: Figure 9.6. (cont.) (c) (d) (a) Fig
Page 203 and 204: Equation 9.7 can also be rewritten
Page 206: (a) (b) Figure 9.10. Energy-absorbi
Page 209 and 210: Figure 9.11. (cont.) (d) The variat
Page 211 and 212: foam filling were evaluated. The re
Page 213 and 214: 13. The interaction between foam fi
Page 215 and 216: Arora, J. S.,2004,Introduction to O
Page 217 and 218: Dannemann, K. A. and Lankford, J.,
Page 219 and 220: Hall, I. W., Guden, M. and Yu, C. J
Page 221 and 222: Kim, D-K. and Lee, S., 1999, Impact
Page 223 and 224: Mamalis, A. G., Manolakos, D. E., I
Page 225 and 226: Pugsley, A. G. and Macaulay, M., 19
Page 227 and 228: T. Miyoshi, M. Itoh S. Akiyama A. K
Page 229: Zhao, H., Elnasri, I. and Girard, Y
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