复合材料/铝复合管轴向准静态及冲击压溃的吸能特性

用数值模拟方法,研究了方形和圆形截面的复合材料/铝复合管在轴向准静态及冲击压溃下的吸能特性,计算得到压溃力-位移曲线。通过将一组方形截面复合管在准静态压溃条件下的计算结果与文献的实验数据进行对比,以验证有限元模型和参数设置的正确性。在铝管的管厚、管长以及截面外周长相同,缠绕不同厚度的复合材料情况下,对比分析了方形和圆形截面复合管在准静态及冲击压溃条件下的轴向压溃吸能特性。结果表明,复合管的截面构型对其吸能效果影响很大,在轴向准静态压溃条件下,圆形截面复合管吸能能力要强于方形截面复合管;冲击压溃吸能量不但与结构自身吸能力有关,还受到外界冲击大小的影响。在设计复合材料层厚度时,需要控制复合管的刚度,避免回弹造成吸能量的降低。     

复合材料吸能圆管在半圆凹槽触发机制下的斜向压溃失效行为

有效的触发机制能诱导并改善复合材料吸能结构的轴向渐进压溃行为,但仍无法解决汽车吸能结构在斜向冲击载荷下的失稳问题。为了提出新的设计来改善失稳行为,对复合材料吸能圆管在半圆凹槽触发机制下的斜向压溃行为和失效机制进行研究。建立引入半圆凹槽触发机制的圆管有限元模型,采用界面和层内非线性损伤演化模型来模拟其真实的压溃失效模式。通过对比模拟和实验对应的轴向压溃载荷、吸能和失效模式来验证圆管的准静态压溃模型。进而,预测斜向压溃角度(10°～50°)对圆管在半圆凹槽触发机制下压溃行为的影响,并详细揭示其轴向和斜向压溃失效机制及其区别。结果表明,压溃载荷、吸能及失效面积随角度增大而明显减小,不稳定的压溃过程使材料失效耗能不充分。圆管在轴向压溃下表现为渐进破坏,而在斜向压溃下以“渐进破坏”向“失稳破坏”过渡为特征,导致斜向压溃载荷与吸能曲线均存在一个过渡。本研究加深了对圆管在外部触发机制下斜向压溃失效机制的理解,为改善斜向压溃失稳行为提供了一定的设计依据。     

引发机制对复合材料波形梁吸能性能的影响及其破坏形貌分析

复合材料正弦波形梁作为复合材料结构2功能一体化的典型构件 , 在结构高强、 高刚和稳定的前提下 ,其压溃峰值应力和稳态损毁吸能行为是设计结构件的关键性能指标 , 而这两个指标与梁的引发机制密切相关。本文中设计了根部打孔削弱机制、 根部预埋倒角机制、 根部非对称梯度削弱和根部对称梯度削弱机制等 3 种不同引发机制 , 通过对正弦波形梁的静态压溃实验及对压溃梁的宏观和微观形貌分析 , 发现引发机制对正弦波形梁的失效引发和稳态损毁模式影响很大 , 根部预埋倒角正弦波形梁的失效引发和稳态损毁吸能效果最好。     

铺层顺序对复合材料薄壁圆管轴向压溃吸能特性的影响研究

采用仿真和试验相结合的方法探讨复合材料薄壁圆管在准静态轴向压缩载荷下的失效吸能特性和吸能机理。首先,建立复合材料薄壁圆管"层合壳"有限元模型,通过显式动力学方法求解其在准静态轴向载荷下的压溃失效力学行为。仿真与试验结果在圆管轴向压溃变形过程、初始峰值载荷、平均压溃载荷及比吸能等主要吸能参数上具有很好的一致性,验证了"层合壳"复合材料圆管有限元模型和建模方法的有效性。其次,采用解析模型与仿真分析方法分别对[0/90]_3s、[0/90/0₂/90₂]_s、[0₃/90₃]_s三种不同铺层顺序的复合材料圆管的屈曲载荷与吸能特性进行了对比,进一步分析了铺层顺序对圆管失效吸能特性的影响。研究表明,0°与90°铺层交替程度对复合材料圆管的吸能特性影响较大,保证纤维失效方式在结构宏观失效中占主导地位能够提高材料失效吸收能量。     

复合材料波纹梁冲击试验与数值模拟

为了探究复合材料波纹梁的吸能性能,针对铺层形式分别为[(±45)3/(0,90)/(±45)3]、[(±45)8]和[(±45)7]的3种复合材料波纹梁元件,进行了动态冲击试验,得到了吸能载荷-位移曲线,并对其损伤破坏形貌进行了分析。以连续损伤力学为基础,结合改进的Hashin损伤判定准则以及损伤演化规律,提出了针对波纹梁耐撞性损伤分析的刚度退化模型,并基于有限元软件平台开发了适用于波纹梁渐进损伤分析的子程序。对3种不同结构形式的波纹梁进行了渐进失效数值分析,模拟得到了能量评估参数比吸能(SEA)和平均载荷值,并将模拟结果与试验结果进行了对比分析。比较分析了不同薄弱环节复合材料波纹梁的吸能能力。结果表明:波纹梁在冲击载荷作用下发生了渐进压溃失效;平均压溃载荷的相对误差不超过12%,能够满足工程应用要求;薄弱环节的设置需综合考虑复合材料性能和铺层方式等因素。     

直升机机身下部复合材料典型结构耐坠特性研究

抗坠性能是武装直升机的一项重要要求,设计具有较高抗坠吸能性能的机身下部结构是实现直升机抗坠要求的主要技术途径。研究了多种形式的复合材料结构元件抗坠特性,在元件研究基础上优化选择复合材料波纹梁和厚蜂窝结构组合,提出了一种新颖的具有较高抗坠吸能性能的复合材料组件形式,并利用有限元理论及试验的方法进行了对比研究分析,计算结果和试验结果吻合较好。     

飞行器机身结构耐撞性分析与设计

耐撞性不仅是飞行器设计中的重要问题,而且还是其取得适航证的必要条件。该文对美国、欧盟和日本等在耐撞性研究方面的研究进行了总结,阐述了耐撞性设计中采用的数值模拟和试验研究方法及其主要问题。主要针对各种飞行器结构耐撞性设计方法进行介绍,对比了轻型固定翼飞机、直升机和大中型民用飞机的耐撞性设计特点。能量吸收结构是耐撞性设计的关键问题之一,对提高飞行器机身能量吸收能力的机身底部结构、机身加强框和客舱地板撑杆结构等设计方法进行详细介绍,总结了飞行器耐撞性可靠性分析和优化设计方法。最后对飞行器结构耐撞性设计的发展作了展望。     

民用飞机地板支撑结构对抗坠撞的影响研究

采用PAM—CRASH瞬态非线性分析软件对斜支撑和无支撑两种不同地板支撑结构形式的机身段进行坠撞仿真分析,通过对机身变形情况及地板滑轨加速度响应结果的对比分析研究,并给出了相关结论。     

汽车双帽型前纵梁设计

试验数据表明,在正面碰撞中前纵梁是主要的吸能部件,因此在耐撞安全性的优化中,对前纵梁的优化十分重要。该文通过使用双帽型新型截面的前纵梁结构提升整车耐撞性能,应用有限元系列软件HyperWorks进行结构性能验证与优化设计。首先,建立双帽梁的轴向压溃简化模型,分析了双帽梁的轴向吸能特性;然后分析了简化模型与整车模型的相关性,提升了计算效率;最后,基于双帽梁的轴向吸能规律,对焊接边宽度参数进行了优化,优化后提高了双帽梁结构的耐撞性能,峰值压溃力减小了4.5%,比吸能增大了5.7%。     

薄弱环节对复合材料波纹梁吸能能力的影响

薄弱环节设置是复合材料吸能结构的关键技术,良好的设计可以使复合材料结构产生稳定的渐进压溃,从而吸收较多的能量.基于波纹梁准静态轴向压溃实验结果,运用MSC/DYTRAN有限元软件建立了三组不同尺寸的碳纤维-环氧树脂波纹梁的有限元模型,在数值模拟结果与实验结果基本吻合的基础上,分析了不同薄弱环节设置对复合材料波纹梁峰值载荷、吸能能力的影响,并进一步比较了不同薄弱环节设置的波纹梁在以6.5m/s的速度碰撞刚性地面时的能量吸能能力.     

Static and dynamic axial crushing of spot-welded thin-walled composite steel–CFRP square tubes

Thin-walled metallic tubular components have long been adopted in the transportation industries, where the stable energy absorbing crushing process provides protection to occupants and cargo in the event of a collision. Fibre–epoxy tubes provide superior strength to weight ratios, however brittle failure modes may limit their energy absorbing capacity under large axial deformation. Composite steel–CFRP (carbon fibre-reinforced polymer) tubes are a recent advent, and combine the benefits of the stable, ductile plastic collapse mechanism of the steel and the high strength to weight ratio of the fibre/resin composite, to form a composite tube with high energy absorption capability. In this paper the applicability of steel–CFRP tubes to structures typical to the automotive industry is investigated. Thin-walled square tubes with width to thickness ratios up to 120 are cold-formed and spot-welded from high strength, low ductility steel, and subjected to static and dynamic axial compression. Four different steel tube geometries and two different carbon fibre matrix layouts are investigated, and comparisons are made between static and dynamic crushing, steel and composite steel–CFRP tubes, and regular and low ductility steels. It is shown that the crashworthiness properties of the steel–CFRP tubes exceed those of the steel tubes, however some issues particular to low ductility steels and such steels under impact conditions prove detrimental to the crashworthiness characteristics. Theoretical procedures are developed to design the crashworthiness characteristics of the composite tubes, and are shown to compare well with the experimental results.     

Finite element modelling of the progressive crushing of braided composite tubes under axial impact

Composite tubular structures are of interest as viable energy absorbing components in vehicular front rail structures to improve crashworthiness. Desirable tools in designing such structures are models capable of simulating damage growth in composite materials. Our model (CODAM for COmposite DAMage), which is a continuum damage mechanics based model for composite materials with physically based inputs, has shown promise in predicting damage evolution and failure in composites. In this study, the model is used to simulate the damage propagation, failure morphology and energy absorption in triaxially braided composite tubes under axial compression. The model parameters are based on results from standard and specialized material testing and a crack band scaling law is used to minimize mesh sensitivity (or lack of objectivity) of the numerical results. Axial crushing of two-ply and four-ply square tubes with and without the presence of an external plug initiator are simulated in LS-DYNA. Refinements over previous attempts by the authors include the addition of a pre-defined debris wedge, a distinguishing feature in tubes displaying a splaying mode of failure, and representation of delamination using a tiebreak contact interface that allows energy absorption through the un-tying process. It is shown that the model adequately predicts the failure characteristics and energy absorption of the crushing events. Using numerical simulations, the process of damage progression is investigated in detail and energy absorptions in different damage mechanisms are presented quantitatively.     

Composite sandwich structures with nested inserts for energy absorption application

Polymer composite sandwich structures are promising candidate structures for reducing vehicle mass, thereby improving the fuel economics. Nonetheless, to fully explore this material as the primary structure and energy absorber in vehicles, it is important to understand the energy absorption capability of this material. Hence, in the present work, comprehensive experimental investigation on the response of composite sandwich structures to quasi-static compression has been carried out. The crashworthiness parameters, namely the peak force, absorbed crash energy, specific absorbed energy, average crushing force and crush force efficiency of various types of composite sandwich structures were investigated in a series of edgewise axial compression tests. The tested composite sandwich specimens were fabricated from glass and carbon fiber with epoxy resin. Four distinct modes of failure were observed and recorded. The primary mode of failure observed was progressive crushing with high energy absorption capability. The optimized design in this study had a specific energy absorption capability of 47.1 kJ/kg with a good crush force efficiency of 0.77, higher than conventional metals.     

A new composite energy absorbing system for aircraft and helicopter

In this paper, an innovative lightweight composite energy-absorbing keel beam system has been developed to be retrofitted in aircraft and helicopter in order to improve their crashworthiness performance. The developed system consists of everting stringer and keel beam. The sub-floor stringers were designed as everting stringer to guide and control the failure mechanisms at pre-crush and post-crush failure stages of composite keel beam webs and core. Polyurethane foam was employed to fill the core of the beam to eliminate any hypothesis of global buckling. Quasi-static axial crushing behaviour of the composite keel beam is investigated experimentally. The results showed that the crushing behaviour of the developed system is found to be sensitive to the change in keel beam web thickness. Laminate sequence has a significant influence on the failure mode types, average crush loads and energy absorption capability of composite keel beam. The desired energy absorbing mechanism revealed that the innovated system can be used for aircraft and helicopter and meet the requirements, together with substantial weight saving.     

一种薄壁吸能结构的设计优化

研究了一种薄壁结构在耐撞指标下的轴向冲击吸能特性。采用非线性有限元软件ABAQUS对结构的冲击过程进行仿真,并结合径向基函数法(RBF),根据耐撞性指标优化了这种吸能结构的截面,得到了较为理想的结构形式。数值结果表明采用该方法可以精确地确定优化参数,使结构比吸能(Es)得到明显提高。     

Numerical investigation of a crash test of a composite helicopter subfloor structure

Composite energy-absorbing aircraft structures are being studied within a European Commission research programme (CRASURV – Design for Crash Survivability). One of the aims of the project is to evaluate the current capabilities of crashworthiness simulation codes for modelling future composite primary structures. In this paper, a detailed analysis is presented of a generic module of a composite helicopter subfloor structure, subjected to crash loading. The analysis is performed with the explicit finite element code PAM-CRASH and is compared with the results of a drop test. It has been found that pre-test simulations with only coupon data as input are capable of providing a reasonable overall representation, but to closely match the behaviour of the test, a significant amount of post-test work is required. The calibration of the post-failure material properties proved to be more crucial than the behaviour up to initial failure. The representation of fabric materials was found to be inadequate and a new fabric material model is under development as a result. The importance of modelling frictional effects was highlighted, and a mesh density study showed the model to be robust over a range of mesh densities.     

典型民机机身段水上冲击数值模拟方法及其耐撞性研究

为了改善民机在紧急迫降情况下的安全性能,对典型机身段水上冲击数值模拟方法及其冲击特性进行了研究。通过合理的简化建立了机身段有限元模型,对有限元方法(FEM)、任意拉格朗日/欧拉方法(ALE)和光滑粒子方法(SPH)水体模型进行了研究,探讨了水体材料模型对机身段结构动态响应特性的影响。在7 m/s垂向冲击速度下,对比分析了水面和刚性地面情况下的机身段结构的耐撞性能。结果表明ALE方法具有最佳计算精度和计算效率。由于忽略了偏应力,采用空材料得到的机身结构响应与弹性流体和弹塑性水体材料有明显不同。在水上冲击过程中,由于水体耗散了大量冲击动能,因此机身加强框变形较小。机身底部蒙皮结构承受较大的均布载荷,因此蒙皮吸能结构吸收了较多的冲击动能,是最重要的吸能结构之一。相对于刚性地面,水面冲击情况下机身具有更小的加速度过载。在紧急迫降情况下,选择湖泊或者江河等水域作为迫降地点可以减小乘员承受加速度过载。     

Effect of natural stitched composites on the crashworthiness of box structures

In the present paper the effects of stitching on the energy absorption and crashworthy behaviour of composite box structures will be studied. The combination of unidirectional carbon fibre-reinforced polymer (CFRP) and glass fibre-reinforced polymer (GFRP) composite materials are used to laminate the composite boxes. Delamination study in Mode-I with the same lay-up was carried out to investigate the effect of stitching on delamination crack growth on energy absorption of stitched and non-stitched composite box structures. The double cantilever beam (DCB) standard test method was chosen for delamination studies. For non-stitched and stitched composite boxes the lamina bending and brittle fracture crushing modes were observed. It was found that the stitched composite boxes which show higher fracture toughness in Mode-I delamination tests, are not necessarily able to absorb more crushing energy in comparison with non-stitched composite boxes. It was also observed that the position of stitched area can affect the crushing mode and consequently energy absorption capability of composite box structures. The main reason can be related to other mechanisms such as bending, friction and bundle fracture which significantly contribute to energy absorption. The analytical model based on energy balance approach is proposed to estimate the mean crushing force, F_m, in axial crushing of square composite box.     

Crushing behaviour of the energy absorbing 'tensor skin' panels

ABSTRACT Research results concerning the simulation of the crushing behaviour of composite systems with energy absorption characteristics are presented in the present work. The study is focused on the ‘tensor skin’ concept, an energy absorbing composite system that was originally developed to improve the crashworthiness of helicopters under water impact and which is promising for utilization in the construction of the lower part of composite fuselage aircraft. The ‘tensor skin’ concept comprises a folded or corrugated composite construction, which upon loading unfolds by forming ‘plastic hinges’, leading to an increase in the load bearing capability of the structure. The numerical modelling issues and the critical aspects of the simulation are discussed. Verification of the numerical simulation procedure is performed by experimental work. The experimental results utilized to assess and validate the numerical procedure were derived within the European Research Project ‘Design for Crash Survivability – CRASURV’ (BRITE – Aeronautics Area). The results of the simulations are generally in good agreement with experimental data.     

新颖圆形多胞复合填充结构的耐撞性

提出一种新颖的圆形多胞复合填充结构,该结构采用蜂窝和泡沫两类材料的交错复合填充。采用实验验证与数值研究相结合的方法,系统地研究了蜂窝和泡沫材料在全填充、部分填充及交互填充结构中的耐撞性。研究结果表明,针对单一材料填充的多胞圆管,部分填充结构比全填充结构具有更好的耐撞性能,其中,环形蜂窝填充结构（H40）和中心泡沫填充结构（F01）具有更优异的能量吸收特性。针对双材料复合填充的多胞圆管,则是中心泡沫填充与环形蜂窝填充的复合结构（F01H40）具有最佳的耐撞吸能性。最后,进一步结合Kriging近似技术与粒子群数值优化方法,对复合填充结构进行多目标优化设计,探索其最优耐撞性与最优参数匹配。结果表明,环形蜂窝部分填充结构（H40）、中心泡沫填充与环形蜂窝填充的复合全填充结构（F01H40）具有最优的耐撞性能。