Axial impact energy absorption characteristics of the aluminum/ carbon fiber reinforced plastic hybrid front rail
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摘要: 为了揭示铝(Al)/碳纤维增强复合材料(CFRP)混合纵梁的吸能机制并提高其抗冲击性能,首先开展了空铝梁及内嵌碳纤维层合板的Al/CFRP混合纵梁动态轴向冲击实验,实验结果表明,相比于单一铝梁,Al/CFRP混合前纵梁的能量吸收
$ {W_{\text{e}}} $ 和比吸能$ {W_{\text{s}}} $ 分别提高46.1%和17.5%。接着,采用MAT54材料模型,在LS-DYNA商用有限元软件中建立相应的有限元模型(FEM),并通过实验数据验证了模型的准确性,揭示了混合结构的能量提升机制及碳板的损伤模式,结果表明混合梁中铝梁和碳板的能量吸收分别比单一铝梁和碳板提高了30.7%和43.4%,混合梁的耗散能比单一组分的摩擦吸能之和提高了217.8%;利用理论模型预测了混合纵梁中铝梁、交互效应及整体的平均压溃反力$ {P_{\text{c}}} $ ,预测结果与仿真结果及实验结果均吻合较好。最后用有限元手段研究了铝梁壁厚、碳板厚度及碳板铺层角度对Al/CFRP混合结构的耐撞性影响,发现混合梁的能量吸收和峰值载荷随着铝梁厚度及碳板厚度的增加而提高。-
关键词:
- 铝合金/碳纤维混合前纵梁 /
- 吸能机制 /
- 理论分析 /
- 轻量化 /
- 有限元
Abstract: To reveal energy absorption mechanism and improve crashworthiness of aluminum (Al)/carbon fiber reinforced plastic (CFRP) hybrid front rails, firstly, the dynamic axial impact tests of net aluminum rails and Al/CFRP hybrid rails with carbon fiber sheets embedded into aluminum hollow were carried out. The experimental results show that the energy absorption$ {W_{\text{e}}} $ and special energy absorption$ {W_{\text{s}}} $ of Al/CFRP hybrid rail are improved by 46.1% and 17.5% compared to the net aluminum rail. Next, the material model MAT54 was adopted to build the finite element model (FEM) in commercial software LS-DYNA and validated by the experimental data. The FEM was used to reveal the mechanism of improvement in energy absorption and the damage mode of the hybrid rail. The result indicates that the$ {W_{\text{e}}} $ of aluminum rail and CFRP laminate in hybrid rail is improved by 30.7% and 43.4% compared to the net corresponding constituent, respectively, and the friction dissipation energy of hybrid rail is improved by 217.8% than that of the sum of single component. Further, a theoretical model is adopted to predict the mean crushing force$ {P_{\text{c}}} $ generated by the aluminum rail, interactive effect and the overall hybrid rail, and the theoretical results are in good agreement with the numerical results and experimental results. Finally, parametric studies of aluminum wall thickness, CFRP laminate thickness and CFRP laminate stacking sequence on the crashworthiness were conducted by the FEM, and results show that the energy absorption and peak crushing force of hybrid rails increase with the increase of aluminum thickness and CFRP thickness. -
图 6 Al/CFRP混合梁的实验与仿真结果对比:(a)载荷-位移曲线; (b)冲击过程;(c)压溃后的混合纵梁正视图;(d)混合梁剖面图
Figure 6. Comparison between numerical and experimental results of Al/CFRP hybrid rail: (a) Force-displacement curves; (b) Impacting process; (c) Front view of hybrid rail after impacting; (d) Sectional view of hybrid rail after impacting
表 1 CFRP层合板(G803-5224)的性能参数
Table 1. Material property parameters of the CFRP laminate (G803-5224)
Material properties Values Density $ \rho $ 1.5 g/cm3 Young’s modulus along x direction $ {E_1} $ 61 GPa Young’s modulus along y、z direction $ {E_2} $ 58 GPa In-plane shear modulus $ {G_1}{\text{ = }}{G_2} $ 3.4 GPa Poisson's ratio $\nu$ 0.056 Tensile strength along x direction $ {X_{\rm{T}} }$ 642 MPa Tensile strength along y direction $ {Y_{\rm{T}}} $ 581 MPa In-plane shear strength $ S $ 87 MPa Failure parameter of tension DFAILT 0.013 Failure parameter of compression DFAILC 0.014 Softening factor SOFT 0.9 Inter-laminar normal strength XNFLS 38.2 MPa Inter-laminar shear strength XSFLS 72.2 MPa 表 2 铝梁与Al/CFRP混合梁实验结果与数值模拟结果对比
Table 2. Comparison between experimental and numerical results of aluminum rail and Al/CFRP hybrid rail
Sample Results $ {W_{\text{e}}} $/kJ $ {P_{\text{e}}} $/kN $ {P_{\text{c}}} $/kN $ {W_{\text{s}}} $/(J·g−1) Al Experiment 5.42 68.86 22.6 8.42 Simulation 5.90 70.10 24.6 9.16 Error 8.85% 1.80% 8.85% 8.79% Al/CFRP Experiment 7.92 78.45 33.0 9.90 Simulation 7.16 77.87 29.8 8.98 Error 9.60% 0.74% 9.70% 9.29% Notes: We—Energy absorption; Pc—Mean crushing force; Pe—Peak crushing force; Ws—Special energy absorption. 表 3 Al/CFRP混合梁实验结果与理论预测结果对比
Table 3. Comparison between experimental and theoretical results of Al/CFRP hybrid rail
Results $ {W_{\text{e}}} $/kJ $ {P_{\text{c}}} $/kN $ {W_{\text{s}}} $/(J·g−1) Experiment 7.92 33.00 9.90 Theory 8.72 36.35 10.91 表 4 Al/CFRP混合梁仿真结果与理论预测结果对比
Table 4. Comparison between simulation and theoretical results of Al/CFRP hybrid rail
Results $ {\overline {{P_{\text{c}}}} _{{\text{Hybrid}}}} $/kN $ {\overline {{P_{\text{c}}}} _{{\text{Al}}}} $/kN $ {\overline {{P_{\text{c}}}} _{{\text{IE}}}} $/kN Simulation 29.80 26.43 8.22 Theory 36.35 27.56 8.79 Notes: $ {\overline {{P_{\text{c}}}} _{{\text{Hybrid}}}} $—Mean crushing force of Al/CFRP hybrid rail; $ {\overline {{P_{\text{c}}}} _{{\text{Al}}}} $—Mean crushing force of Al; $ {\overline {{P_{\text{c}}}} _{{\text{IE}}}} $—Mean crushing force of interactive effect. 表 5 不同混合结构的耐撞性指标汇总
Table 5. Summaries of crashworthiness indicators of different hybrid structures
Specimens Description $ {W_{\text{e}}} $/kJ $ {P_{\text{e}}} $/kN $ {P_{\text{c}}} $/kN $ {W_{\text{s}}} $/(J·g−1) H-TAl−1 TAl=1.25 mm 3.30 43.3 13.75 5.89 H-TAl−2 TAl=1.50 mm 3.85 54.0 16.04 6.03 H-TAl−3 TAl=1.75 mm 5.94 66.4 24.75 8.25 H-TAl−4 TAl=2.00 mm 7.18 77.9 29.92 8.97 H-TAl−5 TAl=2.25 mm 8.19 90.2 34.13 9.28 H-TAl−6 TAl=2.50 mm 9.84 102.0 41.00 10.23 H-TCF−1 TCF=1.00 mm 6.60 75.8 27.50 8.82 H-TCF−2 TCF=1.25 mm 6.83 76.6 28.46 8.83 H-TCF−3 TCF=1.50 mm 7.18 77.9 29.92 8.97 H-TCF−4 TCF=1.75 mm 7.44 79.2 29.92 9.00 H-TCF−5 TCF=2.00 mm 8.00 79.3 33.33 9.39 H-TCF−6 TCF=2.25 mm 8.66 84.6 36.08 9.86 H-TCF−A CF:(+15°/−75°)6 7.18 78.1 29.92 8.97 H-TCF−B CF:(+30°/−60°)6 7.15 78.1 29.79 8.94 H-TCF−C CF:(+45°/−45°)6 6.93 75.5 28.88 8.66 H-TCF−D CF:(+60°/−30°)6 6.77 77.7 28.21 8.46 H-TCF−E CF:(+75°/−15°)6 6.85 77.0 28.54 8.56 H-TCF−F CF:(90°/0°)6 6.83 76.1 28.46 8.53 Notes: H—Hybrid; The number 1, 2, 3, 4, 5, 6 as well as letter A, B, C, D, E, F—Different samples. -
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