An experimental and numerical study on quasi-static and dynamic crashing behaviors for tailor rolled blank (TRB) structures

Sun, Guangyong; Zhang, Huile; Lu, Guoxing; Guo, Jianwen; Cui, Junjia; Li, Qing

doi:10.1016/j.matdes.2016.12.073

Cited by 63 publications

(14 citation statements)

References 44 publications

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“…For example, the axial crushing behavior of steel circular structure was investigated by using experimental and theoretical approaches as early as 1960s . Afterward, the investigations on energy‐absorbing characteristics and crashworthiness were spread to the structures with different geometrical shapes , and the applied loading cases were also multifarious .…”

Section: Introductionmentioning

confidence: 99%

On energy‐absorbing mechanisms of metal/WF‐CFRP hybrid composite columns

Zhu

Zhao

et al. 2020

Polymer Composites

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Hybrid material system, comprised of metal and carbon fiber reinforced plastic (CFRP), combines the excellent mechanical performance and lightweight feature of CFRP with the competitive material cost and superior toughness of metal. By virtue of such mingled feature, metal/CFRP hybrid structure exhibits great potential in automotive components. This study aims to investigate the crushing behavior of aluminum/WF‐CFRP (woven fabric CFRP) hybrid columns subjected to dynamic loading condition by comparing with the corresponding individual columns made of single material (aluminum column and WF‐CFRP column). The dynamic axial crushing tests indicate that specific energy absorption of WF‐CFRP column is 45% higher than that of the aluminum column and 27% superior to that of the hybrid column, while the total energy absorption of the hybrid column is about 8% higher than the summation of WF‐CFRP column and aluminum column. Afterward, several finite element models are developed to reveal the underlying energy‐absorbing mechanisms and the influences of each factor for the hybrid columns. The numerical results show that specific energy absorption of the hybrid columns is negatively correlated with the metal volume fraction (F m), when inner aluminum wall thickness (t m) equals to 1.0 mm. It is also found that crushing process of the hybrid columns with l = 2 (2 CFRP layers) is dominated by the progressive folding of inner aluminum column, leading to a lower damage level of CFRP and lower load carrying capacity. With increasing wrapped CFRP layer number up to 8, the inner aluminum column starts to generate internal inversion deformation mode due to the restriction of the outer CFRP layers, and outer CFRP layers exhibit progressive failure. The energy‐absorbing mechanisms analysis indicates that the internal energy of the internally inversed aluminum column is significantly higher than that of the progressively folded aluminum column, and thus such special deformation mode is capable to offer a more stable and higher load carrying capacity for the hybrid columns. Besides, it is also found that the plastic deformation of the inner aluminum column is the major energy‐absorbing mechanism, which is followed by the crushing failure of outer CFRP layers. The combination mode of thinner aluminum column and thicker CFRP layers tends to offer higher energy‐absorbing capacity, which is much higher than that of the summation of corresponding individual columns. Finally, a complex proportional assessment method is considered to select the optimal configuration achieving the balance of material cost and structural crashworthiness. The present study is expected to provide guideline for design of metal/CFRP hybrid columns.

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Section: Introductionmentioning

confidence: 99%

On energy‐absorbing mechanisms of metal/WF‐CFRP hybrid composite columns

Zhu

Zhao

et al. 2020

Polymer Composites

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“…Sun et al used tailor rolled blank structures to reduce the weight and improve the crashworthiness simultaneously experimentally and numerically. 21 Other scholars have also contributed the field of body structure weight loss. [22][23][24][25][26][27] However, since the body structure of a vehicle is a complex engineering system, the statics and dynamics, crash safety, and the influence of fatigue strength on the multidimensional performance of the system are typically considered independently.…”

Section: Introductionmentioning

confidence: 99%

Study on application of MSOT method for lightweight design of automobile body structure

Wang

2020

Advances in Mechanical Engineering

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In this study, the integrated MSOT (M-Multi-dimensional factor autobody model, S-Screening autobody component, O-Optimization of plate thickness, T-Testing, and validation) integration method is adopted to optimize the automobile body structure design for weight reduction. First, a multi-dimensional factor body model is established, then components of the vehicle are screened for the most important targets related to weight reduction and performance, and a multi-objective optimization is performed. Virtual experiments were carried out to validate the analysis and the MSOT method were proposed for lightweight design of the automobile body structure. A multi-dimensional performance model that considers stiffness, modality, strength, frontal offset collision, and side collision of a domestic passenger car body structure. Components affecting the weight of the vehicle were identified. Sheet metal thickness was selected as the main optimization target and a multi-objective optimization was carried out. Finally, simulations were performed on the body structure. The comprehensive performance, in terms of fatigue strength, frontal offset collision safety, and side collision safety, was verified using the optimized Pareto solution set. The results show that the established MSOT method can be used to comprehensively explore the weight reduction of the body structure, shorten the development process, and reduce development costs.

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“…23 Still others were devoted to the research of lightweight thin-walled energy-absorbing structures, which simultaneously possess excellent lightweight and crashworthiness characteristics. For instance, the following have been exhaustively investigated in the literature: single-cell structures, 24,25 multi-cell structures, 26,27 foam-filled structures, [28][29][30][31] functionally graded structures, 12,13 tailor-welded structures, 32,33 tailor-rolled structures, 34,35 top-hat structures, 33,36 and composite structures. 37,38 Nevertheless, note that lightweight and crashworthiness normally conflict with each other.…”

Section: Introductionmentioning

confidence: 99%

Lightweight optimization of the front end structure of an automobile body using entropy-based grey relational analysis

Xiong

Wang

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part D:

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This study deals with the multi-objective lightweight optimization of the front end structure of an automobile body, as the main assembly to withstand impact force and protect occupants from injuries in frontal collision, based on entropy-based grey relational analysis (EGRA). First, basic noise, vibration, and harshness (NVH) models of the automobile body and crashworthiness models of the vehicle are established and then validated by corresponding actual experiments; hence the lightweight controlling quotas are extracted. Next, the contribution analysis method determines the final parts for lightweight optimization, for which both continuous thickness variables and discrete material variables are simultaneously taken into account. Subsequently, design of experiment (DoE) using the optimal Latin hypercube sampling (OLHS) method is carried out, considering the total mass and the torsional stiffness of the automobile body, the maximum intrusion deformation on the firewall, the maximum impact acceleration at lower end of the B-pillar, and the total material cost of the selected optimization parts as five competing optimization objectives. After that, the optimal combination of thickness and material parameters of the optimization parts is determined using EGRA and confirmed by technique for order preference by similarity to ideal solution (TOPSIS). Finally, a comparison between the original design and the post-lightweight design, namely the optimized design, further confirms the effectiveness of the lightweight optimization. According to the outcomes, the automobile body is lightweight optimized with a mass decrease of 4.98 kg on the basis of well guaranteeing other relevant mechanical performance. Accordingly, the EGRA could be well employed to the multi-objective lightweight optimization of the automobile body.

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An experimental and numerical study on quasi-static and dynamic crashing behaviors for tailor rolled blank (TRB) structures

Cited by 63 publications

References 44 publications

On energy‐absorbing mechanisms of metal/WF‐CFRP hybrid composite columns

On energy‐absorbing mechanisms of metal/WF‐CFRP hybrid composite columns

Study on application of MSOT method for lightweight design of automobile body structure

Lightweight optimization of the front end structure of an automobile body using entropy-based grey relational analysis

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