Crushing energy absorption mechanisms of the composite-metal-foam hybrid tubes under axial and oblique loads
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摘要:
复合材料-金属-泡沫混杂防护结构作为一种新型的吸能结构，结合了复合材料高强度、低密度，金属材料低成本、高韧性和多孔材料稳定变形等优点，在汽车轻量化设计中显示出广阔应用前景。由于不同组分在压溃过程中存在复杂交互作用，其变形模式和相应的吸能机制尚未被完全揭示，为其结构优化设计带了巨大挑战，进一步阻碍了其在汽车领域的推广及应用。本文在实验室条件下制备了单一碳纤维(CF)管件、单一铝管(Al)、单一泡沫铝柱体(Af)、铝-泡沫(Al-Af)及碳纤维-铝合金-泡沫铝(CF-Al-Af)混杂管件，并对其分别开展了轴向(0°)和斜向(10°)准静态压溃实验。结果表明Al-Af混杂管件在轴向和斜向工况下的能量吸收均高于单一组分之和；CF-Al-Af混杂管在斜向工况下的吸能开始超过单一组分之和，说明混杂管件能够产生“1+1>2”的吸能效果。经分析发现单一Al管在轴向和斜向工况下均发生“对称+钻石”混合型变形模式，而混杂管中的Al管在内部Af和外部CF的作用下发生了更为稳定的“对称型”的变形模式，进而促进了混杂管件整体抗压溃能力的提升。最后基于实验结果建立了CF-Al-Af混杂管件及其单一组分轴向工况下的压溃平均载荷的理论预测模型，为后续继续开展其在多工况下的耐撞性设计提供了实验数据及模型支撑。 (a)轴向和(b)斜向加载下碳纤维(CF)-铝合金(Al)-泡沫铝(Af)混杂管件中铝管承载能力提升的机制 Abstract: This study aims to explore the crushing deformation characteristics and underlying energy dissipating mechanisms of carbon-fibre-reinforced plastic (CFRP)-aluminum-aluminum foam hybrid tubes under both axial (0°) and oblique (10°) loads. Quasi-static compressive tests for net CFRP tubes, net aluminum (Al) tubes, net aluminum foams (Af), Al-Af hybrid tubes and CFRP-Al-Af hybrid tubes were performed first; the energy absorptions of the Al-Af hybrid columns are always higher than that of the sum net parts under loading angles of 0° and 10°; the energy absorption of the CF-Al-Af hybrid columns reduces under a 0° loading angle while improves remarkably under a 10° loading angle compared with the sum of net parts. Next, numerical models for these hybrid tubes and the corresponding net parts were developed in LS-DYNA, and numerical results indicate that the energy absorption improvement of Al tubes promotes the load-carrying enhancement of Al-Af and CF-Al-Af hybrid tubes, because the Al tubes in hybrid happen more stable symmetric deformation compared with the “symmetric-diamond” hybrid deformation of the net Al tubes; whereas the energy absorption reductions of external CF tubes primarily decrease energy absorption of CF-Al-Af hybrid tubes, because the CFRP tubes in the hybrid occur axial splitting failure due to compressions of inner Al tubes. Finally, the analytical models on mean crushing forces for CF-Al-Af hybrid columns and corresponding net components under axial load were developed, and the results indicate that the developed analytical models can better predict the mean crushing forces of both hybrid columns and net parts.-
Key words:
- hybrid structure /
- energy absorption /
- quasi-static compression /
- numerical model /
- analytical model
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图 1 铝合金(Al)-泡沫铝(Af)混杂管(a)和碳纤维(CF)-铝合金(Al)-泡沫铝(Af)混杂管(b)制备过程
Figure 1. Manufacturing process of the aluminum(Al)-aluminum foam(Af) hybrid tube (a) and CF-Al-Af hybrid tube (b)
图 3 轴向(0°)和斜向(10°) 实验的典型压溃历程
Figure 3. Typical crushing histories of axial(0°) and oblique(10°) tests
图 4 纯Al、纯Af和纯CF在轴向(0°)和斜向(10°)工况下的载荷-位移曲线
Figure 4. Force-displacement curves of net Al, net Af and net CF tubes under axial(0°) and oblique(10°) loads
图 5 Al-Af混杂管和CF-Al-Af混杂管在轴向(0°)和斜向(10°)工况下的载荷-位移曲线
Figure 5. Force-displacement curves of Al-Af and CF-Al-Af hybrid tubes under axial(0°) and oblique(10°) loads
图 6 单一管件和混杂管件的吸能对比
Figure 6. Comparisons in energy absorption of single and hybrid tubes
图 10 纯铝管(a)、纯泡沫铝(b)、纯碳管(c)、铝管-泡沫铝(d)和碳管-铝管-泡沫铝混杂管(e)仿真与实验曲线对比
Figure 10. Comparisons in curves between experiments and simulations: net Al (a), net Af (b), net CF (c), Al-Af(d) and CF-Al-Af tubes (e)
图 11 纯铝管(a)、纯泡沫铝(b)、纯碳管(c)、铝管-泡沫铝(d)和碳管-铝管-泡沫铝混杂管(e)仿真与实验的变形模式对比
Figure 11. Comparisons in deformation modes between experiments and simulations: net Al (a), net Af (b), net CF (c), Al-Af (d) and CF-Al-Af tubes (e)
图 12 轴向(0°)工况下Al-Af混杂管及其不同组分的能量吸收对比
Figure 12. Comparisons in energy absorptions between Al-Af hybrid tube and its different counterparts under axial(0°) load
图 13 斜向(10°)工况下Al-Af混杂管及其不同组分的能量吸收对比
Figure 13. Comparisons in energy absorptions between Al-Af hybrid tube and its different counterparts under oblique(10°) load
图 14 轴向(0°)工况下CF-Al-Af混杂管及其不同组分的能量吸收对比
Figure 14. Comparisons in energy absorptions between CF-Al-Af hybrid tube and its different counterparts under axial(0°) load
图 15 斜向(10°)工况下CF-Al-Af混杂管及其不同组分的能量吸收对比
Figure 15. Comparisons in energy absorptions between CF-Al-Af hybrid tube and its different counterparts under oblique(10°) load
图 16 轴向(0°)和斜向(10°)工况下混杂管中的Af、Al和CF及相应的单一组分的能量吸收对比
Figure 16. Comparisons in energy absorptions between Af、 Al、CF in hybrid tubes and the corresponding single counterparts under axial(0°) and oblique(0°) loads
图 17 轴向(0°)工况下Al-Af和CF-Al-Af混杂管中的Al及其相应的单一组分的载荷-位移曲线对比
Figure 17. Comparisons in force-displacement curves among Al in Al-Af and CF-Al-Af hybrid tubes and the corresponding single counterparts under axial(0°) load
图 18 轴向(0°)工况下Al-Af和CF-Al-Af混杂管中的Al及其相应的单一组分的变形模式对比
Figure 18. Comparisons in deformation modes among Al in Al-Af and CF-Al-Af hybrid tubes and the corresponding single counterparts under axial(0°) load
图 19 斜向(10°)工况下Al-Af和CF-Al-Af混杂管中的Al及其相应的单一组分的载荷-位移曲线对比
Figure 19. Comparisons in force-displacement curves among Al in Al-Af and CF-Al-Af hybrid tubes and the corresponding single counterparts under oblique(10°) load
图 20 斜向(10°)工况下Al-Af和CF-Al-Af混杂管中的Al及其相应的单一组分的变形模式对比
Figure 20. Comparisons in deformation modes among Al in Al-Af and CF-Al-Af hybrid tubes and the corresponding single counterparts under oblique(10°) load
表 1 所有实验试样的信息汇总
Table 1. Information summary of all testing samples
Samples Outer diameter/mm Thickness
/mmMass
/gLoad
angleAl-0° 60 1.0 58 0° Al-10° 60 1.0 58 10° Af-0° 58 1.0 94 0° Af-10° 58 1.0 94 10° CF-0° 63 1.51 44 0° CF-10° 63 1.51 44 10° Al-Af-0° 60 2.51 102 0° Al-Af-10° 60 2.51 102 10° CF-Al-Af-0° 63 - 195 0° CF-Al-Af-10° 63 - 196 10° 
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表 2 碳纤维复合材料力学性能参数
Table 2. Mechanical property parameters of CFRP
Material property Value Density $ \rho $/(g·cm−3) 1.53 In-plane Young’s modulus $ {E_1} = {E_2} $/GPa 55.4 In-plane shear modulus $ {G_1}{\text{ = }}{G_2} $/GPa 3.4 Poisson's ratio $ \nu $ 0.056 Tensile strength along weft direction $ {X_{\text{T}}} $/MPa 455 Tensile strength along warp direction $ {Y_{\text{T}}} $/MPa 405 Failure parameter of tension $ {D_{{\text{FAILT}}}} $ 0.05 Failure parameter of compression $ {D_{{\text{FAILC}}}} $ −0.05 Softening factor $ {S_{{\text{OFT}}}} $ 0.5 Inter-laminar stiffness $ {G_{\text{N}}} $/MPa 40000 Inter-laminar critical distance $ {C_{{\text{CRIT}}}} $/mm 0.005 Inter-laminar normal strength $ {X_{{\text{NFLS}}}} $/MPa 38.2 Inter-laminar shear strength $ {X_{{\text{SFLS}}}} $/MPa 72.2
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表 3 实验与仿真的耐撞性指标对比
Table 3. Comparisons in crashworthiness indicators between experiments and simulations
Samples Tests $ {E_{\text{A}}} $
/J$ {P_{{\text{CF}}}} $
/kN$ {C_{{\text{FE}}}} $
/%Al-0° Experiment 1735.20 61.52 39 Simulation 1785.60 58.43 42 Al-10° Experiment 1634.40 29.86 76 Simulation 1605.60 31.99 70 Af-0° Experiment 1191.60 17.12 84 Simulation 1282.32 21.35 83 Af-10° Experiment 1200.24 18.77 83 Simulation 1131.12 17.33 91 CF-0° Experiment 3191.04 55.74 80 Simulation 3175.92 55.31 80 CF-10° Experiment 2665.44 47.91 77 Simulation 2676.07 37.92 98 Al-Af-0° Experiment 3502.77 46.87 84 Simulation 3287.23 64.00 71 Al-Af-10° Experiment 3573.77 57.04 87 Simulation 3304.81 56.27 82 CF-Al-Af-10° Experiment 5723.28 143.50 55 Simulation 5405.04 134.66 56 CF-Al-Af-10° Experiment 5803.92 116.47 69 Simulation 5573.52 99.76 78
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表 4 实验结果与有限元和理论预测结果对比
Table 4. Comparisons among test and theory and FEA results
Tube Method $ M_{_{{\rm{net Al}}}}^{{\rm{CF}}} $
/kN$ M_{{\rm{net Af}}}^{{\rm{CF}}} $
/kN$ M_{{\rm{net CF}}}^{{\rm{CF}}} $
/kN$ M_{{\rm{IE}}}^{{\rm{CF}}} $
/kN$ M_{{\rm{CF - Al - Af}}}^{{\rm{CF}}} $
/kNCF-Al-Af-0° Test 24.10 16.55 44.32 −5.48 79.49 FEA 24.80 17.81 44.11 −11.65 75.07 |Error| 2.90% 7.61% 0.47% 112.5% 5.56% Theory 24.15 17.96 47.55 −2.27 87.39 |Error| 0.21% 8.52% 7.29% 58.6% 9.9%
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