Mesoscopic hybrid design and crashworthiness properties of thin-walled energy-absorbing tubes
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摘要: 随着交通事故和能源消耗等问题的日益突显，轻质薄壁吸能结构成为碰撞防护领域重要的研究方向。本研究考虑传统金属材料及复合材料的吸能特点，提出了一种纤维/金属交错铺层的细观混杂复合材料薄壁圆管设计方法。通过非均匀缠绕铺设和一体化成型方法，制备了混杂圆管试样。通过轴向压缩和落锤冲击实验，测试了结构准静态和动态力学响应。采用多种耐撞性能指标量化分析了力学响应曲线，并与金属试样进行了对比。结果表明：纤维/金属细观混杂设计可有效提高薄壁吸能结构的比吸能，降低吸能平台的载荷波动。准静态加载下，碳纤/铝混杂圆管比吸能提升了约54.3%，吸能效率增加至0.8。动态冲击下，玻纤/铝混杂圆管保持了准静态失效模式，比吸能提升了约24.7%，吸能效率保持在0.44。本研究验证了纤维/金属细观混杂铺层在碰撞防护领域的应用潜力，为轻质薄壁吸能结构设计提供了新思路与参考实例。Abstract: With the increasing issues of traffic accidents and energy security, lightweight thin-walled energy-absorbing structures have emerged as a crucial subject in the field of collision protection. In this research, a novel design for thin-walled mesoscopic hybrid tubes with composite/metal interleaved layers was proposed, considering the mechanical characteristics of metal and composite materials. A series of hybrid samples were fabricated through a non-uniform winding method. The quasi-static and dynamic mechanical responses were tested through axial compression and drop-weight impact experiments. Various crashworthiness indices were utilized to quantitatively analyze the mechanical performances. The results demonstrate that the composite/metal mesoscopic hybrid design effectively enhances the specific energy absorption and reduces the load fluctuation. In the quasi-static loading state, the carbon fiber/aluminum hybrid tubes show an increase in specific energy absorption by approximately 54.3% compared with the aluminum and an energy efficiency improvement to 0.8. In the dynamic impact state, the glass fiber/aluminum hybrid tubes maintain the same failure modes with quasi-static. The specific energy absorption increases by approximately 24.7% and the energy efficiency maintains at 0.44. This research validates the application potential of composite/metal mesoscopic hybrid design in the field of collision protection, providing new insights and reference examples for the lightweight thin-walled energy-absorbing structures.
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图 1 薄壁吸能结构在各领域中的应用
Figure 1. Application of thin-walled energy-absorbing structures in various fields
图 2 纤维/铝合金细观混杂圆管的一体成型制备
Figure 2. The integrated molding method of fiber/aluminum alloy mesoscopic hybrid tubes
图 3 不同内径尺寸的均质材料和纤维/铝细观混杂圆管试样
Figure 3. Homogeneous and fiber/aluminmum alloy mesos mesoscopic hybrid tubes with different diameters
图 5 典型载荷-位移曲线与耐撞性能指标对应关系
Figure 5. The correspondence between typical load-displacement curve and crashworthiness indices
图 7 碳纤玻纤复合材料薄壁圆管的准静态压缩响应曲线
Figure 7. Quasi-state compression curves of carbon and glass fiber composite tubes
图 8 复合材料薄壁圆管试样准静态压缩失效模式
Figure 8. The failure modes of composite tubes under quasi-state compression
图 9 纤维/铝细观混杂薄壁圆管的准静态压缩响应曲线：(a)碳纤/铝混杂；(b)玻纤/铝混杂
Figure 9. Quasi-state compression curves of composite/aluminum hybrid tubes: (a) carbon fiber /aluminium hybrid; (b) glass fiber /aluminium hybrid
图 10 纤维/铝混杂薄壁圆管的准静态压缩失效模式：(a)碳纤/铝混杂；(b)玻纤/铝混杂；(c)电子显微镜观察损伤形貌；(d)摄像机观察压缩失稳现象
Figure 10. Quasi-static compression failure mode of composite/aluminum hybrid tubes: (a) carbon fiber /aluminium hybrid; (b) glass fiber /aluminium hybrid; (c) SEM failure morphology; (d) structural buckling performance
图 11 薄壁圆管试样的落锤冲击响应：(a)铝合金圆管；(b)碳纤复合材料圆管；(c)玻纤复合材料圆管；(d)碳纤/铝混杂圆管；(e)玻纤/铝混杂圆管
Figure 11. Impact response of thin-walled tubes: (a) aluminium alloy; (b) carbon fiber reinforced composite; (c) glass fiber reinforced composite; (d) carbon fiber /aluminium hybrid; (e) glass fiber /aluminium hybrid
图 12 冲击载荷下各类薄壁圆管试样冲击载荷失效模式
Figure 12. Failure modes of various thin-walled tubes under impact load
表 1 均质薄壁圆管与纤维/铝细观混杂结构的试样结构参数
Table 1. Specific structural parameters of homogeneous and mesoscopic hybrid tubes
Type Specimen number Height/
mmDiameter/
mmThickness/
mmMass/
gDensity/
(g·cm−3)Ply stacking sequence 6061-Al tubes Al-D41 80 41 2.00 55.93 2.56 - - Al-D56 80 56 2.00 74.33 Al-D76 80 76 2.00 99.77 Homogeneous tubes CF-D40 80 40 1.96 27.60 1.35 [CF]8 ■■■■■■■■ CF-D60 80 60 1.90 40.52 CF-D80 80 80 1.90 52.34 GF-D40 80 40 2.15 38.44 1.68 [GF]8 □□□□□□□□ GF-D60 80 60 2.20 57.27 GF-D80 80 80 2.20 77.24 Mesoscopic hybrid tubes CAC-D40 80 40 1.96 29.32 1.46 [CF2/Al/CF]S ■■Α■■Α■■ CAC-D60 80 60 1.90 43.84 CAC-D80 80 80 1.90 58.20 GAG-D40 80 40 1.93 37.65 1.88 [GF2/Al/GF]S □□Α□□Α□□ GAG-D60 80 60 1.92 56.25 GAG-D80 80 80 1.92 74.80 Notes: ■ represents carbon fiber composite; □ represents glass fiber composite; “A” represents aluminmum. 
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表 2 薄壁圆管试样的各类耐撞性指标汇总
Table 2. Summary of crashworthiness parameters for thin-walled tubes
Type Specimen number SEA/(kJ∙kg−1) PCF/kN MCF/kN CFE Al alloy Al-D41 35.58 58.35 33.48 0.57 Al-D56 32.31 77.71 40.78 0.53 Al-D76 28.48 108.34 48.36 0.47 CFRP CF-D40 58.11 48.74 27.02 0.56 CF-D60 55.85 61.23 38.54 0.64 CF-D80 54.11 88.23 48.61 0.56 CF/Al hybrid CAC-D40 54.91 33.69 26.87 0.80 CAC-D60 48.81 48.29 35.64 0.74 CAC-D80 41.62 70.27 40.24 0.57 GFRP GF-D40 50.72 83.84 33.49 0.40 GF-D60 50.45 125.82 50.17 0.40 GF-D80 46.73 176.31 61.93 0.35 GF/Al hybrid GAG-D40 43.03 50.38 27.00 0.54 GAG-D60 18.49 74.31 17.35 0.23 GAG-D80 12.30 79.91 15.38 0.20 Notes: SEA represents the specific energy absorption; PCF represents the peak crushing force; MCF represents the mean crushing force; CFE represents crushing force efficiency.
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表 3 动态冲击下薄壁圆管试样的各类耐撞性指标汇总
Table 3. Summary of crashworthiness parameters for thin-walled tubes under dynamic impact
Type Specimen number SEA/(kJ∙kg−1) PCF/kN MCF/kN CFE Al alloy Al-D41 36.13 83.46 42.27 0.51 Al-D56 34.39 89.68 43.31 0.48 Al-D76 31.55 125.09 48.03 0.38 CFRP CF-D40 46.11 62.94 21.44 0.35 CF-D60 46.20 79.07 31.88 0.42 CF-D80 40.18 105.22 36.10 0.35 CF/Al hybrid CAC-D40 40.24 45.96 16.69 0.43 CAC-D60 39.20 73.21 28.62 0.40 CAC-D80 36.78 106.11 35.56 0.34 GFRP GF-D40 49.10 76.03 32.42 0.43 GF-D60 43.25 81.54 43.01 0.53 GF-D80 43.19 116.76 57.24 0.50 GF/Al hybrid GAG-D40 45.05 62.99 28.27 0.44 GAG-D60 17.75 83.03 16.66 0.32 GAG-D80 13.81 94.23 17.26 0.23 Notes: SEA represents the specific energy absorption; PCF represents the peak crushing force; MCF represents the mean crushing force; CFE represents crushing force efficiency.
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