Deformation modes and crashworthiness energy absorption of sinusoidally corrugated tubes manufactured by direct metal laser sintering

Alkhatib, Sami E.; Matar, Mohammad S.; Tarlochan, Faris; Laban, Othman; Mohamed, Ahmed; Alqwasmi, Nouman

doi:10.1016/j.engstruct.2019.109838

Cited by 51 publications

(21 citation statements)

References 40 publications

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“…Qualitative assessment includes the structure’s overall crushing behaviour, the composites’ force–displacement properties and failure mechanisms exhibited by the structure. Quantitative analysis includes quantifying crashworthiness characteristics that allow one to have an idea of the structure’s energy-absorbing capabilities [ 26 ]. Some essential parameters that reflect a structure’s crashworthy characteristics are detailed below.…”

Section: Methodsmentioning

confidence: 99%

Effect of Fibre Orientation on the Quasi-Static Axial Crushing Behaviour of Glass Fibre Reinforced Polyvinyl Chloride Composite Tubes

2021

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In this study, glass fibre reinforced (GFRP) polyvinyl chloride (PVC) tubes were subjected to quasi-static axial compression tests to determine their crashworthiness performance. To this end, this study employed GFRP/PVC tubes with four different fibre orientations, 45°, 55°, 65° and 90°. A five-axis filament winding machine was used to fabricate the tubes. The results show that there was a considerable increase in all crashworthiness characteristics due to GFRP reinforcement. For the GFRP/PVC composite tubes of different fibre orientations, the load-bearing capacity, crush force efficiency and energy absorption capability generally improve with increasing fibre orientation. The GFRP/PVC 45° specimen was a notable exception as it exhibited the best specific energy absorption capacity and a crushing force efficiency that was only slightly less than for the GFRP/PVC 90° specimen.

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Section: Methodsmentioning

confidence: 99%

Effect of Fibre Orientation on the Quasi-Static Axial Crushing Behaviour of Glass Fibre Reinforced Polyvinyl Chloride Composite Tubes

2021

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“…The Initial Peak Force (IPF) parameter was used to indicate the amount of load required to initiate a permanent deformation in the structure [ 18 ]. In addition, great attention was directed to its instantaneous Crash Force Efficiency (CFE) [ 15 ]. This is expressed as the ratio of average force to the IPF, and it mainly reflects the stability of the structure in carrying the load throughout the compression stroke.…”

Section: Experimental Methodologymentioning

confidence: 99%

“…Indeed, the DMLS offers more capability to create non-prismatic and functionally graded elements or microstructures [ 1 , 14 ]. However, it is well known it is more energy consuming and requires post-preparation steps [ 15 ]. Nevertheless, the material handling and overall cost are also favoring polymeric AM techniques [ 16 ].…”

Section: Introductionmentioning

confidence: 99%

A Comparative Study between Polymer and Metal Additive Manufacturing Approaches in Investigating Stiffened Hexagonal Cells

et al. 2021

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Recent polymer and metal additive manufacturing technologies were proven capable of building complex structures with high accuracy. Although their final products differ significantly in terms of mechanical properties and building cost, many structural optimization studies were performed with either one without systematic justification. Therefore, this study investigated whether the Direct Metal Laser Sintering (DMLS) and Fused Deposition Modelling (FDM) methodologies can provide similar conclusions when performing geometrical manipulations for optimizing structural crashworthiness. Two identical sets of four shapes of stiffened hexagonal cells were built and crushed under quasi-static loading. The results were compared in terms of collapsing behavior, load-carrying performance, and energy-absorption capability. Although the observed failure modes were different since the base-materials differ, similar improvement trends in performance were observed between both fabrication approaches. Therefore, FDM was recommended as a fabrication method to optimize thin-walled cellular hexagonal parameters since it was 80% more time-efficient and 53.6% cheaper than the DMLS technique.

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“…For example, the crashworthiness requirements for electrical vehicles is different from traditional vehicles [1] because additional safety features are required to protect the battery cells. In terms of designing for crashworthiness, a lot of work has been conducted looking into various material, shapes, sizes, and loading conditions [2][3][4][5][6][7][8][9][10][11][12][13][14][15][16]. Several composite sandwich designs such as inserts and foam-core hybrid composites were tested and it was found that these configurations have good energy absorption capabilities [2,6,15,16].…”

Section: Introductionmentioning

confidence: 99%

“…Composite corrugated tubes were also found to have excellent crushing behavior which corresponded to good energy absorption capabilities [5,11,12]. Some researchers [7,8,10] studied metal corrugated tubes produced by traditional manufacturing techniques and by additive manufacturing.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Validation of Numerical Model for Top-Hat Tubular Structure Subjected to Axial Crush

Abdulqadir

Tarlochan

2021

Applied Sciences

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Vehicle crashworthiness is an important aspect to consider when designing a vehicle to ensure the safety of the occupants. Besides this, vehicles are also designed to reduce weight for better fuel economics. One possible approach to reducing weight without compromising vehicle safety is by looking at new designs and usage of composite materials, along with the usage of computational models to reduce time and cost. Hence, this paper displays the experimental results of a carbon fiber reinforced closed top-hat section subjected to both quasi-static and dynamic crushing loading. The results were used to validate the computational model developed in the study. The specimens were made of carbon composite prepregs MTM-44 sheets stacked at the alternative orientation of ±45° and 0°/90°, where 0° direction coincides with the axis of the member. The samples were prepared by using a mold and carbon prepregs under vacuum bagging followed by curing in an autoclave. Trigger initiation was applied to ensure the specimens demonstrated a stable crushing mode of failure during the test. Experimental investigations were carried out under the ambient conditions with different loading conditions, and different kinetic energy ranges (2, 3 and 6 kJ). Experimental data was used to validate the finite element analysis (FEA). The maximum errors obtained between experimental and FEA for mean load, mean energy absorption, and crushing displacement were 13%, 13% and 7%, respectively. The numerically obtained results were in strong agreement with the experimental data and showed that they were able to predict the failure of the specimens. The work also showed the novelty of using such structures for energy absorption applications.

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Deformation modes and crashworthiness energy absorption of sinusoidally corrugated tubes manufactured by direct metal laser sintering

Cited by 51 publications

References 40 publications

Effect of Fibre Orientation on the Quasi-Static Axial Crushing Behaviour of Glass Fibre Reinforced Polyvinyl Chloride Composite Tubes

Effect of Fibre Orientation on the Quasi-Static Axial Crushing Behaviour of Glass Fibre Reinforced Polyvinyl Chloride Composite Tubes

A Comparative Study between Polymer and Metal Additive Manufacturing Approaches in Investigating Stiffened Hexagonal Cells

An Experimental Validation of Numerical Model for Top-Hat Tubular Structure Subjected to Axial Crush

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