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TABLE OF CONTENTS LIST OF FIGURES .......................................................................................................... x LIST OF TABLES .......................................................................................................... xx CHAPTER 1. INTRODUCTION .................................................................................. 1 CHAPTER 2. AL CLOSED CELL FOAMS PROCESSING AND CRUSHING BEHAVIOR ...................................................................... 6 2.1. Introduction ............................................................................................. 6 2.2. Processing of Al Closed Cell Foams ...................................................... 7 2.1.1. Foaming Melts by Gas Injection (Alcan/Cymat or Hydro Process) ............................................................................................ 8 2.1.2. Gas Releasing Particle Decomposition in the Melts (Alporas Process) .......................................................................................... 10 2.1.3. Gas Releasing Particle Decomposition in Semi-Solids (Fraunhofer and the Alulight Process) ........................................... 12 2.1.4. Accumulative Roll-Bonding ........................................................ 14 2.1.5. Laser Assisted Foaming .............................................................. 15 2.3. Mechanical Behavior of Closed Cell Foams ........................................ 16 CHAPTER 3 CRUSHING BEHAVIOR OF TUBULAR STRUCTURES UNDER AXIAL DEFORMATIONS ................................................... 31 3.1. Introduction ........................................................................................... 31 3.2. Crushing Behavior of Empty Circular Tubes ....................................... 32 3.3. Crushing Behavior of Empty Square and Rectangular Tubes .............. 42 3.4. Crushing Behavior of Foam Filled Tubes ............................................. 48 3.5. Motivations ........................................................................................... 63 vi
CHAPTER 4 EXPERIMENTAL DETAILS .............................................................. 65 4.1. Compression Testing of Aluminum Foam ............................................ 65 4.2. Empty and Aluminum Foam Filled 1050Aluminum Crash Boxes ....... 67 4.3. Tensile Testing of 1050H14 Al ........................................................... 72 4.4. Compression Tests of Crash Boxes ...................................................... 73 4.5. Quasi-static Compression Testing of Empty and Aluminum Foam Filled 1050Aluminum Crash Boxes ........................................... 74 4.5.1. Uniaxial compression testing of <strong>crash</strong> <strong>boxes</strong> at different strain rates ...................................................................................... 74 4.5.2. Uniaxial Compression Testing of Empty Original Crash Boxes ............................................................................................. 75 4.5.3. Uniaxial Compression Testing of Empty and Partially Foam Filled Crash Box without Montage Parts ....................................... 75 4.5.4. Uniaxial Compression Testing of Empty and Partially Foam Filled Crash Box with Montage Plates .......................................... 77 4.6. Initial Dynamic Testing of Empty and Aluminum Foam Filled 1050Aluminum Crash Boxes with Fixing Plates .................................. 79 CHAPTER 5 SIMULATION AND OPTIMIZATION OF EMPTY AND PARTIALLY ALUMINUM FOAM FILLED CRASH BOXES ......... 81 5.1. Material Modeling ................................................................................ 81 5.1.1. 1050H14 Base Material ................................................................. 81 5.1.2. Aluminum Foam Modeling ........................................................... 84 5.2. Quasi-static and Dynamic Simulation of Crashing Behavior of Empty and Foam Filled 1050H14 Al Crash Box .................................. 87 5.3. The response surface methodology ....................................................... 90 5.4. The Crashworthiness optimization of tubular structures ...................... 96 5.5. Optimization of 1050H14 Al crush box – Alulight Al foam filler binary system ........................................................................................ 98 vii
Page 1 and 2: OPTIMIZATION OF THE AXIAL CRUSHING
Page 3 and 4: ACKNOWLEDGEMENTS My PhD quest has b
Page 5: ÖZET KAPALI HÜCRELİ ALUMİNYUM K
Page 9 and 10: CHAPTER 8 ALUMINUM CRASH BOX OPTIMI
Page 12 and 13: Figure 3.7. Simulations of the defo
Page 14 and 15: Figure 4.9. Dimensions of tensile t
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
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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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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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