薄壁结构轴向冲击能量吸收性能分析与改进设计
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摘要
冲击能量吸收性能对于结构在冲击、爆炸等极端载荷工况下的安全性能至关重要。薄壁结构由于具有较高的能量吸收效率,已经成为工程中广泛应用的和重要的冲击能量吸收结构形式。薄壁结构的能量吸收行为与结构形式,材料特性以及载荷工况等因素存在复杂而敏感的关系。理解薄壁结构在冲击载荷下的能量吸收机理与变形模式,提出具有高能量吸收性能的新型结构形式,一直是科研工作者及工程师关心的问题,尤其是汽车工业领域。基于该需求,本论文研究了薄壁结构在低速冲击下的能量吸收行为,建立了改进能量吸收性能的薄壁结构横截面非凸化方法,并提出了具有高能量吸收性能的非凸截面薄壁管和非凸多胞管；提出了基于仿生的非凸薄壁管能量吸收性能改进设计的方法,给出了具有高能量吸收性能的含分段增强板的非凸薄壁结构；采用多胞化性能改进机理,研究了圆柱夹层多胞管。具体研究内容和成果如下。
(1)提高薄壁结构能量吸收性能的截面非凸化设计方法以及非凸薄壁结构轴向冲击能量吸收性能研究。通过对高性能薄壁能量吸收结构所具有的特点的分析,发现了传统凸多边形薄壁管在能量吸收性能方面的局限性,提出了突破这一局限性并提高薄壁结构能量吸收性能的截面非凸化设计方法。根据该方法设计了一类非凸薄壁结构,并采用数值模拟考察了其在轴向冲击下的能量吸收性能。数值模拟结果表明非凸薄壁管在轴向冲击下的能量吸收性能显著优于传统的方管。采用超折叠单元理论推导了非凸截面薄壁管在轴向冲击下的平均载荷理论预测公式,并指出了简化的超折叠单元方法的局限性。采用有限元分析对基于超折叠单元方法所推导的平均力理论预测公式进行了验证。同时还讨论了非凸截面薄壁管在壁厚较大情况下的膨胀—收缩非紧凑变形模式问题。
(2)非凸薄壁管与多胞方管轴向冲击的能量吸收对比研究。对比研究了方管,多胞方管和非凸管在轴向冲击下的能量吸收性能。并且,开展了这三类薄壁管在等材料用量,等能量吸收及等最大初始峰值力三种特定性能需求情况下的能量吸收性能研究。发现多胞方管和非凸截面管无论是能量吸收效率和载荷一致性方面都明显优于传统方管。多胞方管和非凸截面管在轴向压缩下的折叠波长都明显小于方管,因此,在相同的结构长度内能形成更多皱褶,从而提高能量吸收。与多胞方管比,非凸截面管在能量吸收效率上也有明显优势。更重要的是非凸截面管结构形式简单,具有可制造性好的优势。
(3)非凸多胞管轴向冲击能量吸收性能研究。结合截面多胞化和截面非凸化这两种提高薄壁管能量吸收性能的方法,提出了一类非凸截面多胞管。非凸截面多胞管同时从截面外轮廓及截面内部增加了截面折角数目,并且保持折角处相邻壁板夹角保持在最优范围内。使得分布在变形剧烈的折角附近的材料比例大幅度增加从而提高结构的能量吸收效率。将超折叠单元方法推广到截面的四板交叉的十字形部分,推导了非凸多胞管轴向压缩能量吸收性能理论预测公式。理论公式与采用有限元数值模拟结果相一致。研究表明,非凸截面多胞管能量吸收性能优于方管、多胞方管及非凸截面管,还可在一定程度上避免非凸截面管潜在的整体膨胀—收缩非紧凑变形问题。
(4)基于仿生的非凸薄壁管能量吸收性能改进设计方法与含分段增强板的非凸薄壁结构冲击能量吸收性能研究。根据竹子具有节及节隔膜的构型特征,探讨了竹节及节隔膜对于提高竹子结构的承载力的作用。受竹节及节隔膜大幅度提高竹横向强度的启发,提出了一种仿生横隔板加强的非凸薄管。比较了这类仿生结构与方管及非凸截面管在轴向冲击时的能量吸收性能,发现这类新型仿生结构不仅能保持非凸薄壁管能力吸收性能高的特点,也能有效抑制其截面整体膨胀—收缩非紧凑变形。研究了这类结构的横隔板数及壁厚对能量吸收的影响,发现能使仿生非凸薄壁管产生渐进稳定变形的最少横隔板数时的结构具有最佳的能量吸收效率。研究表明,含有类似竹节的横向隔板的仿生非凸薄壁管在轴向冲击下,能量吸收能力强,变形模式稳定,是一类高性能的薄壁能量吸收结构。
(5)薄壁圆柱夹层多胞管轴向冲击下的能量吸收性能研究。根据方管和圆管在轴向冲击下能量吸收的结构有效率公式,发现圆管的结构有效率明显高于方管,并分析了其原因。引入截面面积系数,改进了结构密实度的定义,使得几何等效结构具有相同的密实度值。受圆管能量吸收性能高的启发,研究了一类圆柱夹层多胞管。通过数值模拟发现圆柱夹层多胞管与类似参数的方形多胞管比,其能量吸收能力提高约一半。对圆柱夹层多胞管的几何构形进行了参数分析,发现其结构壁厚、环向胞元数目和胞元层数都对能量吸收性能有显著的影响。
本文工作得到国家自然科学基金项目90816025、国家重点基础研究(973)计划课题2011CB610304、国家重大科技专项2009ZX04014-034的资助,在此表示感谢。
Energy absorption of structures is essential for security service of structures if extreme load conditions such as explosion and impact occure. Thin-walled structures are used widely as kinetic energy absorbers as they are high energy absorption and weight efficient. Numerious investigations are carried out to explore energy absorption of thin-walled structures to meet the strong demand of the automotive industry. Howerer, the energy absorption behavior for most type of thin-walled structures under impact load is still not clear, due to the complexity of this problem. The energy absorption of thin-walled structures is closely relate to factors such as structural configuration, material properties and load conditions. It is still a major goal for scientists and engineers to understand the energy absorption mechnism and deformation mode of thin-walled structures and guide their industrial applications. In this thesis, the following aspects to the energy absorption behavior of thin-walled structures under low velocity impact are investigated. A strategy named non-convexity of cross-section is proposed and two types of thin-walled structures named as non-convex multi-corner columns (abbr. NCMC) and non-convex multi-cell columns (abbr. NCMCELL) are developed. A type of bio-inspired bulkhead reinforced non-convex multi-corner columns (abbr. BI-NCMC) and A type of cylindrical multi-cell columns (abbr. CMC)are proposed. The main contents and conclusions of this dissertation are as follows:
(1) Cross-section non-convexity and energy absorption of non-convex multi-corner thin-walled columns subjected to axial crushing. A strategy to improve energy absorption efficiency of thin-walled columns by introducing extra non-convex corners on the cross section is proposed. Several profiles of NCMC obtained through this strategy are presented and their energy absorption capacities under axial crush are investigated analytically and numerically. Explicit formulations for predicting the mean crushing force of NCMC are derived based on the theory of Super Folding Element (abbr.SFE) method, and the predicting results of these formulations have good agreement with the numerical simulation performed by explicit non-linear finite element method. The comparisons of the NCMC and square column show that the former behaves better energy absorption performance.
(2) Comparative study of energy absorption performance of NCMC and multi-cell square columns (abbr. SMC)subject to axial crushing. Energy absorption of NCMC subject to axial crush is investigated, and their performance is compared with square and SMC. First, the three type of columns with the same wall thickness is investigated using explicit non-linear finite element software ANSYS/LS-DYNA. And then, investigation of their energy absorption performance under three different requirements is carried out, which are the same amount of material usage, the same energy absorption and the same maximum peak crushing force. The results show, NCMC are superior to square column as energy absorber no matter in specific energy absorption or crush force efficiency. NCMC performance better than SMC except for crush force efficiency in some cases.
(3) Axial crushing of non-convex multi-cell columns. A strategy to improve energy absorption efficiency of thin-walled columns is proposed, which is by introducing extra non-convex corners as well as introducing internal webs in the cross section. Both the two ways increases the material distribution proportion near severe deformation corners, which can improve energy absorption efficiency of structure. Several NCMCELL obtained through this strategy are presented and their energy absorption capacities under axial crush are investigated analytically and numerically. Explicit formulations for predicting the mean crushing force of NCMCELL are derived based on the theory of Super Folding Element method. Numerical simulation performed by explicit non-linear finite element method shows that the NCMCELL subjected to axial crash deforms progressively and absorbs a large amount of energy. The comparisons of the NCMCELL with square, NCMC and SMC show that the NCMCELL behaves better in energy absorption.
(4) Energy absorption of boi-inspired bulkhead reinforced non-convex multi-corner columns. A type of BI-NCMC is proposed to improve energy absorption performance. First, the non-compact expansion-contraction deformation mode of NCMC subjected to axial crush is discussed. And then, transverse bulkheads are introduced to restrain the non-compact expansion-contract deformation mode, which is inspired by the phenomenon of bamboo node and nodal diaphragm enhanced the transverse strength of bamboo. Energy absorption of this type of BI-NCMC is investigated numerically. Progressive deformation mode is achieved and this structure shows high energy absorption performance. The role of the transverse bulkheads is to change the deformation mode from expansion-contract mode to progressive mode, while the energy absorption of the bulkheads is little. Finally, a parametric analysis of the column is carried out, and it is found that the column with highest energy absorption efficiency is the one with least transverse bulkheads and still maintain progressive deformation mode.
(5) Energy absorption of cylindrical multi-cell columns. The structural effectiveness of circular tube and square tube is compared and the forner peforms better than the latter. A modified solidity ratio based on the cross-section area coefficient is difined to ensure the geometric equivalent structure with the same value of solidity ratio. A type of CMC is proposed to improve energy absorption performance, which is inspired by the high energy absorption performance of circular tube. Numerical examples illustrate that CMC is more efficient than square column and SMC in energy absorption. In addition, a parametric study is conducted to investigate the influence of geometrical parameters on crashworthiness. And it is found that the wall thickness, the number of cells alone the radial and circumferential directions have a distinct effect on the energy absorption.
This research is supported by National Natural Science Foundation of China (No.90816025), National Basic Research Program (973Program) of China (No.2011CB610304) and National Science and Technology Major Project of the Ministry of Science and Technology of China (No.2009ZX04014-034).The financial supports are greatly acknowledged.
(1)提高薄壁结构能量吸收性能的截面非凸化设计方法以及非凸薄壁结构轴向冲击能量吸收性能研究。通过对高性能薄壁能量吸收结构所具有的特点的分析,发现了传统凸多边形薄壁管在能量吸收性能方面的局限性,提出了突破这一局限性并提高薄壁结构能量吸收性能的截面非凸化设计方法。根据该方法设计了一类非凸薄壁结构,并采用数值模拟考察了其在轴向冲击下的能量吸收性能。数值模拟结果表明非凸薄壁管在轴向冲击下的能量吸收性能显著优于传统的方管。采用超折叠单元理论推导了非凸截面薄壁管在轴向冲击下的平均载荷理论预测公式,并指出了简化的超折叠单元方法的局限性。采用有限元分析对基于超折叠单元方法所推导的平均力理论预测公式进行了验证。同时还讨论了非凸截面薄壁管在壁厚较大情况下的膨胀—收缩非紧凑变形模式问题。
(2)非凸薄壁管与多胞方管轴向冲击的能量吸收对比研究。对比研究了方管,多胞方管和非凸管在轴向冲击下的能量吸收性能。并且,开展了这三类薄壁管在等材料用量,等能量吸收及等最大初始峰值力三种特定性能需求情况下的能量吸收性能研究。发现多胞方管和非凸截面管无论是能量吸收效率和载荷一致性方面都明显优于传统方管。多胞方管和非凸截面管在轴向压缩下的折叠波长都明显小于方管,因此,在相同的结构长度内能形成更多皱褶,从而提高能量吸收。与多胞方管比,非凸截面管在能量吸收效率上也有明显优势。更重要的是非凸截面管结构形式简单,具有可制造性好的优势。
(3)非凸多胞管轴向冲击能量吸收性能研究。结合截面多胞化和截面非凸化这两种提高薄壁管能量吸收性能的方法,提出了一类非凸截面多胞管。非凸截面多胞管同时从截面外轮廓及截面内部增加了截面折角数目,并且保持折角处相邻壁板夹角保持在最优范围内。使得分布在变形剧烈的折角附近的材料比例大幅度增加从而提高结构的能量吸收效率。将超折叠单元方法推广到截面的四板交叉的十字形部分,推导了非凸多胞管轴向压缩能量吸收性能理论预测公式。理论公式与采用有限元数值模拟结果相一致。研究表明,非凸截面多胞管能量吸收性能优于方管、多胞方管及非凸截面管,还可在一定程度上避免非凸截面管潜在的整体膨胀—收缩非紧凑变形问题。
(4)基于仿生的非凸薄壁管能量吸收性能改进设计方法与含分段增强板的非凸薄壁结构冲击能量吸收性能研究。根据竹子具有节及节隔膜的构型特征,探讨了竹节及节隔膜对于提高竹子结构的承载力的作用。受竹节及节隔膜大幅度提高竹横向强度的启发,提出了一种仿生横隔板加强的非凸薄管。比较了这类仿生结构与方管及非凸截面管在轴向冲击时的能量吸收性能,发现这类新型仿生结构不仅能保持非凸薄壁管能力吸收性能高的特点,也能有效抑制其截面整体膨胀—收缩非紧凑变形。研究了这类结构的横隔板数及壁厚对能量吸收的影响,发现能使仿生非凸薄壁管产生渐进稳定变形的最少横隔板数时的结构具有最佳的能量吸收效率。研究表明,含有类似竹节的横向隔板的仿生非凸薄壁管在轴向冲击下,能量吸收能力强,变形模式稳定,是一类高性能的薄壁能量吸收结构。
(5)薄壁圆柱夹层多胞管轴向冲击下的能量吸收性能研究。根据方管和圆管在轴向冲击下能量吸收的结构有效率公式,发现圆管的结构有效率明显高于方管,并分析了其原因。引入截面面积系数,改进了结构密实度的定义,使得几何等效结构具有相同的密实度值。受圆管能量吸收性能高的启发,研究了一类圆柱夹层多胞管。通过数值模拟发现圆柱夹层多胞管与类似参数的方形多胞管比,其能量吸收能力提高约一半。对圆柱夹层多胞管的几何构形进行了参数分析,发现其结构壁厚、环向胞元数目和胞元层数都对能量吸收性能有显著的影响。
本文工作得到国家自然科学基金项目90816025、国家重点基础研究(973)计划课题2011CB610304、国家重大科技专项2009ZX04014-034的资助,在此表示感谢。
Energy absorption of structures is essential for security service of structures if extreme load conditions such as explosion and impact occure. Thin-walled structures are used widely as kinetic energy absorbers as they are high energy absorption and weight efficient. Numerious investigations are carried out to explore energy absorption of thin-walled structures to meet the strong demand of the automotive industry. Howerer, the energy absorption behavior for most type of thin-walled structures under impact load is still not clear, due to the complexity of this problem. The energy absorption of thin-walled structures is closely relate to factors such as structural configuration, material properties and load conditions. It is still a major goal for scientists and engineers to understand the energy absorption mechnism and deformation mode of thin-walled structures and guide their industrial applications. In this thesis, the following aspects to the energy absorption behavior of thin-walled structures under low velocity impact are investigated. A strategy named non-convexity of cross-section is proposed and two types of thin-walled structures named as non-convex multi-corner columns (abbr. NCMC) and non-convex multi-cell columns (abbr. NCMCELL) are developed. A type of bio-inspired bulkhead reinforced non-convex multi-corner columns (abbr. BI-NCMC) and A type of cylindrical multi-cell columns (abbr. CMC)are proposed. The main contents and conclusions of this dissertation are as follows:
(1) Cross-section non-convexity and energy absorption of non-convex multi-corner thin-walled columns subjected to axial crushing. A strategy to improve energy absorption efficiency of thin-walled columns by introducing extra non-convex corners on the cross section is proposed. Several profiles of NCMC obtained through this strategy are presented and their energy absorption capacities under axial crush are investigated analytically and numerically. Explicit formulations for predicting the mean crushing force of NCMC are derived based on the theory of Super Folding Element (abbr.SFE) method, and the predicting results of these formulations have good agreement with the numerical simulation performed by explicit non-linear finite element method. The comparisons of the NCMC and square column show that the former behaves better energy absorption performance.
(2) Comparative study of energy absorption performance of NCMC and multi-cell square columns (abbr. SMC)subject to axial crushing. Energy absorption of NCMC subject to axial crush is investigated, and their performance is compared with square and SMC. First, the three type of columns with the same wall thickness is investigated using explicit non-linear finite element software ANSYS/LS-DYNA. And then, investigation of their energy absorption performance under three different requirements is carried out, which are the same amount of material usage, the same energy absorption and the same maximum peak crushing force. The results show, NCMC are superior to square column as energy absorber no matter in specific energy absorption or crush force efficiency. NCMC performance better than SMC except for crush force efficiency in some cases.
(3) Axial crushing of non-convex multi-cell columns. A strategy to improve energy absorption efficiency of thin-walled columns is proposed, which is by introducing extra non-convex corners as well as introducing internal webs in the cross section. Both the two ways increases the material distribution proportion near severe deformation corners, which can improve energy absorption efficiency of structure. Several NCMCELL obtained through this strategy are presented and their energy absorption capacities under axial crush are investigated analytically and numerically. Explicit formulations for predicting the mean crushing force of NCMCELL are derived based on the theory of Super Folding Element method. Numerical simulation performed by explicit non-linear finite element method shows that the NCMCELL subjected to axial crash deforms progressively and absorbs a large amount of energy. The comparisons of the NCMCELL with square, NCMC and SMC show that the NCMCELL behaves better in energy absorption.
(4) Energy absorption of boi-inspired bulkhead reinforced non-convex multi-corner columns. A type of BI-NCMC is proposed to improve energy absorption performance. First, the non-compact expansion-contraction deformation mode of NCMC subjected to axial crush is discussed. And then, transverse bulkheads are introduced to restrain the non-compact expansion-contract deformation mode, which is inspired by the phenomenon of bamboo node and nodal diaphragm enhanced the transverse strength of bamboo. Energy absorption of this type of BI-NCMC is investigated numerically. Progressive deformation mode is achieved and this structure shows high energy absorption performance. The role of the transverse bulkheads is to change the deformation mode from expansion-contract mode to progressive mode, while the energy absorption of the bulkheads is little. Finally, a parametric analysis of the column is carried out, and it is found that the column with highest energy absorption efficiency is the one with least transverse bulkheads and still maintain progressive deformation mode.
(5) Energy absorption of cylindrical multi-cell columns. The structural effectiveness of circular tube and square tube is compared and the forner peforms better than the latter. A modified solidity ratio based on the cross-section area coefficient is difined to ensure the geometric equivalent structure with the same value of solidity ratio. A type of CMC is proposed to improve energy absorption performance, which is inspired by the high energy absorption performance of circular tube. Numerical examples illustrate that CMC is more efficient than square column and SMC in energy absorption. In addition, a parametric study is conducted to investigate the influence of geometrical parameters on crashworthiness. And it is found that the wall thickness, the number of cells alone the radial and circumferential directions have a distinct effect on the energy absorption.
This research is supported by National Natural Science Foundation of China (No.90816025), National Basic Research Program (973Program) of China (No.2011CB610304) and National Science and Technology Major Project of the Ministry of Science and Technology of China (No.2009ZX04014-034).The financial supports are greatly acknowledged.
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