仿生多分支薄壁吸能器结构设计与吸能机理研究

Structural design and energy absorption mechanism research of bionic multi-branch thin-walled energy absorber

  • 摘要: 针对传统薄壁吸能器存在的峰值力过高、吸能效率低等问题,本研究依托仙人掌多肋条拓扑的载荷分散与抗屈曲特性,设计一种仿生多分支薄壁吸能器结构。首先结合超折叠单元理论揭示其茎干与肋条的协同承载来实现冲击载荷的均匀传递与能量逐级耗散的吸能机理。然后通过ABAQUS建立有限元模型,在4 m/s的低速冲击工况下,系统分析其变形模式、碰撞力响应与能量吸收特性并基于Kriging模型与NSGA-II算法进行多目标优化,获得最优结构参数组合。结果表明:优化后的仿生多分支吸能器较传统方形吸能器在低速碰撞下表现出“低峰值力-高吸能-高承载力”的性能优势,峰值碰撞力降低了23.8%,平均碰撞力提升到79.98 kN,比吸能提升124.5%。采用激光粉末床熔融增材制造技术和正交试验标定3D打印态6061铝合金Johnson-Cook本构参数,并通过准静态压缩实验验证了仿真模型的准确性,仿真与实验相对误差低于7%。本研究为汽车吸能器的仿生设计提供了理论依据与技术支撑。

     

    Abstract: To address the excessive peak force and low energy absorption efficiency of conventional thin-walled energy absorbers, this study proposes a biomimetic multi-branch thin-walled energy absorber inspired by the load-dispersing and anti-buckling characteristics of the multi-rib topology of cactus stems. First, the energy absorption mechanism of the proposed structure was elucidated based on the super-folding element theory, revealing that the synergistic load-bearing effect between the central stem and peripheral ribs enables uniform impact load transfer and progressive energy dissipation. Subsequently, a finite element model was established in ABAQUS to systematically investigate the deformation mode, crushing force response, and energy absorption characteristics under a low-speed impact condition of 4 m/s. A multi-objective optimization framework combining a Kriging surrogate model and the NSGA-II algorithm was then developed to obtain the optimal structural parameter combination. The results show that, compared with the conventional square energy absorber, the optimized biomimetic multi-branch energy absorber exhibits superior crashworthiness under low-speed impact, characterized by reduced peak force, enhanced energy absorption, and improved load-bearing capacity. Specifically, the peak crushing force was reduced by 23.8%, the mean crushing force increased to 79.98 kN, and the specific energy absorption increased by 124.5%. In addition, the Johnson–Cook constitutive parameters of 3D-printed 6061 aluminum alloy were calibrated through laser powder bed fusion additive manufacturing and orthogonal experiments. The accuracy of the finite element model was further validated by quasi-static compression tests, with the relative discrepancy between the simulation and experimental results below 7%. This study provides a theoretical basis and technical support for the biomimetic design of automotive energy absorbers.

     

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