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CHAPTER 6 EXPERIMENTAL RESULTS ............................................................ 100 6.1. Uniaxial Compression Behavior of Alulight Closed-Cell Al Foam Materials ................................................................................... 100 6.2. Tension test of 1050H14 Al Crash Box Base Material ...................... 103 6.3. Tension test of welded 1050H14 Al Base Crash Box Material .......... 104 6.4. Compression Testing of Commercial Crash Boxes ............................ 105 6.5. Quasi-static Testing of Empty and Al Foam Filled 1050Al Crash Boxes .................................................................................................. 107 6.5.1. Compression Tests of Empty Crash Box with and without Trigger Mechanism ...................................................................... 107 6.5.2. Compression of Empty Original Crash Box ................................ 109 6.5.3. Compression Tests of Empty and Partially Foam Filled Crash Box without Montage Parts ............................................... 111 6.5.4. Uniaxial Compression Testing of Empty and Partially Foam Filled Crash Box with Montage Parts .......................................... 120 6.6. Dynamic Testing of Empty and Al Foam Filled 1050 Al Crash Boxes. ................................................................................................. 128 CHAPTER 7 MODELING RESULTS OF FOAM, EMPTY AND AL FOAM FILLED CRASH BOX .......................................................... 132 7.1. Simulation Results of Al Foam Modeling .......................................... 132 7.2. Evaluation of the Material Models for 1050H14 Al Base Material ............................................................................................... 133 7.3. Simulation of Empty and Partially Foam Filled Crash Box without Montage Parts ........................................................................ 135 7.4. Simulation of Empty and Partially Foam Filled Crash Box with Montage Parts ..................................................................................... 144 7.5. Dynamic Testing of Empty and Al Foam Filled 1050Al Crash Boxes .................................................................................................. 157 viii
CHAPTER 8 ALUMINUM CRASH BOX OPTIMIZATION ................................. 159 8.1. Optimization Results ........................................................................... 159 8.2. Optimization of Partially Filled Crush Box with 6061T4 Al and Hydro Foam Filler .............................................................................. 164 CHAPTER 9 DISCUSSION ..................................................................................... 171 9.1. Comparison of mean load values ........................................................ 171 9.2. Stroke efficiency of crash boxes ......................................................... 175 9.3. Crush force efficiency of crash boxes ................................................. 176 9.4. Total efficiency of crash boxes ........................................................... 180 9.5. Foam filling efficiency of crash boxes ............................................... 181 9.6. SEA analysis of crash boxes ............................................................... 186 CHAPTER 10 CONCLUSIONS ................................................................................. 190 REFERENCES ............................................................................................................. 194 APPENDIX Objective Functions for Partially Filled Alulight and Hydro Foam Filled 1050H14 and 6061T4 Al Crash Boxes .......................... 210 ix
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: CHAPTER 4 EXPERIMENTAL DETAILS ....
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
Page 57 and 58: 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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