The finite element modelling of metal foam structures have proven to be a difficult task. Many different modelling approaches exist, both for creating the CAD model and for performing the finite element simulations. This article details the CAD and finite element modelling of an existing aluminum foam. To model the cell structure, the Weaire-Phelan unit cell was used. The different parameters of the unit cell were adjusted to fit the parameters of the existing foam. The physical properties of the finished model were then compared to the original specimen to validate its accuracy. After the comparison, it was determined, that the Weaire-Phelan unit cell can be used to model the physical properties of the structure. The validated and simplified model was then used to perform a finite element analysis under compressive loading. The results were compared to the compression test results of the existing aluminum foam. By comparing the results and calculating the relative errors, it was determined that both the physical and the mechanical properties of metal foam structures can be modelled using this exact method with significant accuracy.
The research is dedicated to determine one of the most important mechanical properties which is the Young's modulus. Its value is crucial for clearly explaining and understanding the results of any mechanical loading experiment. Three cylindrical samples of 15 mm height and 7.5 mm diameter were designed using SpaceClaim application in the ANSYS Software and then 3D printed using Direct Metal Laser Sintering via EOS M 290 3D printer. The specimens were then tested under compression in order to determine the value of the Young's modulus for titanium alloy of grade 23 (Ti, Al, V, O, N, C, H, Fe, Y). The finite element method was executed using ANSYS mechanical to run a comparison between laboratory results with nominal results of the Young's modulus. Young's modulus value is affected by the 3D printing accuracy and quality, the material's quality as well; however, the deviation is within 10%.
Taking into consideration the additional weight of a vehicle, today’s requirements can only be met using new materials and designs. The application of metal foam is one of the most promising methods of enhancing the impact energy absorption ability of the crumple zone. The energy-absorbing capacity of thin-walled structures filled with metal foams during compression can be notably improved, which results in lower loading on the passengers. The main goal of our research is to develop a new design that is suited to absorb more impact energy while taking into consideration weight optimization. The authors wanted to unveil the effect of the inhomogeneous filler material in these thin-walled structures. Therefore, the present study investigates the compression test of two metal foams of different densities, in different ways. In the first section, the foams were compressed independently from each other by a recording of a stress–strain diagram. After the single compression, the foams were loaded together, first in parallel, and subsequently in a serial scheme. The study aimed to reveal the effect of the parallel and serial compression scheme focusing on the sum of impact energy absorption.
One of the most critical issues during polymer finite element simulations is the selection of the proper material models. The widely used and accepted multilinear material models require load case-specific material tests, which are time and cost demanding. Data for these characteristics must be acquired by standardized measurements. On the other hand, the parameters required to create a linear elastic material model in most cases are easy to obtain, and the establishment of the model is a shorter process. This research is aimed to provide information to engineers about the possibility of modeling the nonlinear elastic materials by using linear elastic material models and about the limits of such models. To create the most accurate material models, laboratory measurements were performed on polyamide (PA6) material, which is a widely used raw material in the industry. Test specimens were manufactured to obtain material constants according to the ISO 527-2 standard, and for validating the effectiveness of the applied material models, three different tensile specimens were created, which were tested under quasi-static loading in the elastic region. A comprehensive finite element investigation was performed, and the numerical results were then compared to laboratory measurements using the GOM Aramis digital image correlation (DIC) system. By comparing the optically measured strain data to the numerical results, it was determined that the nonlinear elastic materials can be modeled using linear elastic models in a well identifiable strain range with sufficient accuracy.
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