A key property in the manufacture of toecaps for protective footwear is resistance to impacts, deformations, and cracking, as the resulting defects may lead to serious workplace accidents involving the lower extremities. The present paper proposes a new approach to qualitative verification of toecap design based on numerical simulations of impact tests. Computational experiments were conducted for toecaps made from different materials (AISI 10450, S235, S355 and A36 steels, as well as Lexan polycarbonate) and characterized by different geometries, which were recreated by 3D scanning. The impact resistance of the toecaps was analyzed using a numerical model simulating an experimental impact test. The results were used to determine the location of critical stresses and to plot equivalent stress maps for the studied toecaps. The finite element analysis of the impact tests was carried out with an explicit elastoplastic finite element code: ANSYS (Ansys, Inc., Canonsburg, PA, USA) with the Explicit Dynamics module of the Workbench solver. The presented analysis of the impact resistance of toecaps by the finite element method for impact simulation may be used to optimize the spatial geometry of toecaps and to verify the construction of toecaps and the material deformations that may occur. In addition, it could eliminate unsuitable materials that are likely to undergo dangerous deformations, and draw attention to the deformation caused by the impact of the toecaps used in footwear in the working environment.
Przedmiotem prac modelowych i badań doświadczalnych jest kompozytowa skorupa nośna fotela kolejowego. Zaprojektowano kształt geometryczny i strukturę materiałową konstrukcji oraz dobrano materiały. Do budowy skorupy wykorzystano kompozyty włókniste o osnowie polimerowej (kompozyty FRP – Fiber Reinforce Polimer), które są lżejsze w porównaniu ze stalą i jednocześnie zapewniają odpowiednie standardy z zakresu wytrzymałości i bezpieczeństwa. Opracowano obliczeniowy model skorupy i przeprowadzono analizę wytrzymałościową zgodnie z wytycznymi branżowej normy oraz hipotezami wytrzymałościowymi dotyczącymi kompozytów FRP. Obliczenia przeprowadzono za pomocą oprogramowania ANSYS (Ansys Composite PrepPost), bazującego na metodzie elementów skończonych. W artykule przedstawiono analizę wytrzymałościową zoptymalizowanego modelu kompozytowej skorupy nośnej fotela. Na podstawie wytycznych z prac modelowych wytworzono model fizyczny (walidacyjny), w technologii laminowania próżniowego na gorąco. Walidację doświadczalną modelowania z wynikiem pozytywnym przeprowadzono na stanowisku badawczym firmy S.Z.T.K. TAPS – Maciej Kowalski. Słowa kluczowe: konstrukcja fotela kolejowego, kompozyt FRP, test wytrzymałościowy, modelowanie MES, walidacja doświadczalna
The subject of the modelling work and the conducted experiments is the composite shell of a train seat. The activities carried out involved designing the geometry, planning the material structure, and selecting the materials to be used. The shell was built using polymer matrix fibrous composites (i.e. FRP – Fibre Reinforced Polymer – composites), which are lighter than steel and comply with the relevant standards for strength and safety at the same time. This was followed by creating a computational model for the shell and conducting a strength analysis in accordance with the guidelines of the relevant industry standard and strength hypotheses adopted for FRP composites. The calculations were conducted using ANSYS Composite PrepPost software based on the finite element method. The article offers a strength analysis of an optimised composite shell of a train seat. Based on the guidelines obtained as a result of the conducted modelling work, a physical prototype (validation model) of the seat was created. Hot vacuum lamination technology was applied in the production process. The experimental validation of the model, producing a positive result, was conducted using a test stand owned by S.Z.T.K. TAPS – Maciej Kowalski. Keywords: train seat structure, FRP composite, FEM modelling, experimental validation
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