Insight into the physics of foam densification via numerical simulation

Foamed materials are increasingly finding application in engineering systems on account of their unique properties. The basic mechanics which gives rise to these properties is well established, they are the result of collapsing the foam microstructure. Despite a basic understanding, the relationship between the details of foam microstructure and foam bulk response is generally unknown. With continued advances in computational power, many researchers have turned to numerical simulation to gain insight into the relationship between foam microstructure and bulk properties. However, numerical simulation of foam microscale deformation is a very challenging computational task and, to date, simulations over the full range of bulk deformations in which these materials operate have not been reported. Here a particle technique is demonstrated to be well-suited for this computational challenge, permitting simulation of the compression of foam microstructures to full densification. Computations on idealized foam microstructures are in agreement with engineering guidelines and various experimental results. Dependencies on degree of microstructure regularity and material properties are demonstrated. A surprising amount of porosity is found in fully-densified foams. The presence of residual porosity can strongly influence dynamic material response and hence needs to be accounted for in bulk (average) constitutive models of these materials.     

Microstructure and Tensile Mechanical Properties of Anisotropic Rigid Polyurethane Foam

An understanding of the mechanical properties of solid foams facilitates effective use of such materials, which are often deployed in load-bearing applications such as impact absorbers, cushioning and sandwich structures. This study is an experimental investigation that focuses on the deformation response of rigid polyurethane foam to tension. Microstructural features such as the size and geometry of constituent cells and the struts that define the cell edges, as well as their stiffness and tensile strength, are examined. The nature of cell deformation and fracture are identified through microscopy and the associated micromechanics analyzed. Results show that the cells are elongated and thus the foam exhibits anisotropic properties. Flexure of the struts that define the cell edges is the primary mechanism governing deformation and failure. Information on the mechanical, microstructural and deformation characteristics elicited through this investigation will facilitate formulation of idealized cell-based models to account for the mechanical response of rigid polymeric foams.     

基于三维细观力学模型的开孔泡沫弹性性能预测

泡沫材料的宏观力学性能主要取决于基体材料的力学特性及其微细观结构特征,基于细观力学模型的分析方法是泡沫材料力学性能研究的重要途径。文中基于Matlab语言和Abaqus软件构建了描述中等孔隙率开孔弹性泡沫材料微结构特征的三维随机分布球形泡孔模型,并采用有限元方法对弹性泡沫压缩变形进行了模拟,并计算给出了不同孔隙率弹性泡沫材料弹性模量、剪切模量、体积模量以及泊松比的分布,建立了相应的唯象表达式。与理论模型及测试结果的比较表明,本文基于三维随机泡孔模型模拟结果构建的唯象表达式能够对弹性泡沫材料的弹性力学性能给出很好的预测。     

DETERMINATION OF CELLULAR FOAM MATERIAL PROPERTIES FOR USE IN FINITE ELEMENTS ANALYSIS

A simple method for determining volumetric stress/strain relationship has been developed for structural foams. This procedure yields information that can be used in FEA for foam-like materials, up to the start of the densification.
The simulation and test data show a good correlation up to the start of material densification. This is because the material model in the computer code ABAQUS is only capable of modeling a bilinear response and does not address densification effects.
No attempt was made to study strain rate effects. They don't appear to be significant in this particular foam material, but may be important in other structural foams under high speed impact.     

Modeling and prediction of bulk properties of open-cell carbon foam

The emerging ultralightweight material, carbon foam, was modeled with three-dimensional microstructures to develop a basic understanding in correlating microstructural configuration with bulk performance of open-cell foam materials. Because of the randomness and complexity of the microstructure of the carbon foam, representative cell ligaments were first characterized in detail at the microstructural level. The salient microstructural characteristics (or properties) were then correlated with the bulk properties through the present model. In order to implement the varying anisotropic nature of material properties in the foam ligaments, we made an attempt to use a finite element method to implement such variation along the ligaments as well as at a nodal point where the ligaments meet. The model was expected to provide a basis for establishing a process-property relationship and optimizing foam properties.The present model yielded a fairly reasonable prediction of the effective bulk properties of the foams. We observed that the effective elastic properties of the foams were dominated by the bending mode associated with shear deformation. The effective Young's modulus of the foam was strongly influenced by the ligament moduli, but was not influenced by the ligament Poisson's ratio. The effective Poisson's ratio of the foam was practically independent of the ligament Young's modulus, but dependent on the ligament Poisson's ratio. The effective Young's modulus of the carbon foam was dependent more on the transverse Young's modulus and the shear moduli of the foam ligaments, but less significantly on the ligament longitudinal Young's modulus. A parametric study indicated that the effective Young's modulus was significantly improved by increasing the solid modulus in the middle of the foam ligaments, but nearly invariant with that at the nodal point where the ligaments meet. Therefore, appropriate processing schemes toward improving the transverse and shear properties of the foam ligaments in the middle section of the ligaments rather than at the nodal points are highly desirable for enhancing the bulk moduli of the carbon foam.     

Propagation of compaction waves in metal foams exhibiting strain hardening

One-dimensional models for compaction of cellular materials exhibiting strain hardening are proposed for two different impact scenarios. The models reveal the characteristic features of deformation under the condition of decreasing velocity during the impact event. It was established that an unloading plastic wave of strong discontinuity propagates in the foam and it has a significant dynamic effect on the foam compaction and energy absorption. The proposed models are based on the actual experimentally derived stress strain curves. The compaction mechanism in three aluminium based foam materials, two of them with relatively low density – Alporas and Cymat with 9% and 9.3% relative density, respectively and a higher density Cymat foam with 21% relative density, is analysed. Numerical simulations were carried out to verify the proposed models.The predictions of the proposed models are compared with published analytical models of compaction of cellular materials which assume a predefined densification strain. It is shown that the approximation of a cellular material with significant strain hardening by the Rigid Perfectly-Plastic-Locking (RPPL) model can lead to an overestimation of the energy absorption capacity for the observed stroke due to the non-uniform strains along the compacted zone of the actual material in contrast to the predefined constant densification strain in the RPPL model. The assumption of a constant densification strain leads also to an overestimation of the maximum stress, which occurs under impact.     

A stochastic constitutive model for disordered cellular materials: Finite-strain uni-axial compression

A stochastic constitutive model is developed for describing the continuum-scale mechanical response of disordered cellular materials. In the present work, attention is restricted to finite-strain uni-axial compression under quasi-static loading conditions. The development begins with an established cellular-scale mechanical model, but departs from traditional modeling approaches by generalizing the cellular-scale model to accommodate finite strain. The continuum-scale model is obtained by averaging the cellular-scale mechanical response over an ensemble of foam cells. Various stochastic material representations are considered through the use of probability density functions for the relevant material parameters, and the effects of the various representations on the continuum-scale response are investigated. Combining cellular-scale mechanics with a stochastic material representation to derive a continuum-scale constitutive model offers a promising new approach for simulating the finite-strain response of cellular materials. Results demonstrate that increasing a material’s degree of polydispersity can produce the same stiffening effects as increasing the initial solid-volume fraction. Additionally, particular stochastic material representations are shown to provide upper and lower bounds on the mechanical response of the cellular materials under investigation, while suitable choices for the stochastic representation are shown to accurately reproduce experimental stress–strain data through the large deformations associated with densification.     

Saint-Venant decay rates for a non-homogeneous isotropic mixture of elastic solids in anti-plane shear

The purpose of this research is to investigate the influence of material inhomogeneity on the decay of Saint-Venant end effects in anti-plane shear deformations of linear isotropic mixtures of elastic solids. The work is motivated by the recent research activity on functionally graded materials (FGMs), i.e. materials with spatially varying properties tailored to satisfy particular engineering applications. The spatial decay of solutions of a boundary value problem with variable coefficients on a semi-infinite strip is investigated. The results may be interpreted in terms of a Saint-Venant principle for anti-plane shear deformations of linear isotropic mixtures of elastic solids.     

Non-elliptic elastic materials and the modeling of dissipative mechanical behavior: an example

In the context of a special problem, this paper investigates the possibility of modeling dissipative mechanical response in solids on the basis of the equilibrium theory of finite elasticity for materials that may lose ellipticity at large strains. Quasi-static motions for such materials are in general dissipative if the associated equilibrium fields involve discontinuous displacement gradients. For the problem treated, consideration of such deformations is shown to lead naturally to an internal variable formalism similar to those used to describe macroscopic plastic behavior arising from microstructural effects. For quasi-static motions which are maximally dissipative in a specified sense, this formalism leads to a mechanical response which resembles that associated with the pseudo-elastic effect in shape-memory alloys.     

Deformation rate effects on failure modes of open-cell Al foams and textile cellular materials

The compressive behavior of open-cell aluminum alloy foam and stainless steel woven textile core materials have been investigated at three different deformation rate regimes. Quasi-static compressive tests were performed using a miniature loading frame, intermediate rates were achieved using a stored energy Kolsky bar, and high strain rate tests were performed using a light gas gun.In agreement with previous studies on foam materials, the strain rate was not found to have a significant effect on the plateau stress of metallic foams. For all the tests, real time imaging of the specimen combined with digital image correlation analysis allowed the determination of local deformation fields and failure modes. For the Kolsky bar tests, the deformations in the foam specimen were found to be more distributed than for the quasi-static test, which is attributed to moderate inertia effects. The differences in failure mode are more dramatic for the gas gun experiments, where a full compaction shock wave is generated at the impact surface. The stresses in front and behind the shock wave front were determined by means of direct and reverse gas gun impact tests, i.e., stationary and launched specimen, respectively. A one-dimensional shock wave model based on an idealized foam behavior is employed to gain insight into the stress history measurements. We show that the predictions of the model are consistent with the experimental observations. Woven textile materials exhibited moderate dependence of strength on the deformation rate in comparison with open-cell foam materials.     

Indentation into polymeric foams

The effects of the nose shape of rigid indenters on the indentation behaviour of polymethacrylimide (PMI) and polyetherimide (PEI) foams with different densities are investigated. Experimental results show that indentation resistance depends on the geometry of the indenter and the density of the foam. Analytical models based on the deformation mechanisms observed in experiments are developed to predict the indentation resistance. It shows that the analytical predictions are in good agreement with experimental measurements for a range of polymeric foams. This study presents a complete and systematic experimental data on the indentation behaviours of a range of polymeric foams and demonstrates the capability of the analytical model to predict the indentation behaviours of PMI and PEI foams.     

Effective elastic behavior of some models for perfect cellular solids

The effective elastic behavior of some models for low density cellular solids, or solid foams, are calculated using analytical and numerical techniques. The models are perfect in the sense that imperfections or irregularities as often encountered in real foams have been removed. We believe that the present models can serve as references to which more advanced models which include imperfections and irregularities can be compared. The work in this paper does not address buckling or yielding in cell walls, which play an increasingly important role as foam stresses increase.     

Foam rheology: Relation between extensional and shear deformations in high gas fraction foams

A two-dimensional hexagonal foam cell model is used to derive analytic expressions for the bulk stress tensor and foam microstructure for any small homogeneous deformation. We show that calculations done for deformations where the principal axes of stress and strain coincide, such as in extension, are sufficient to provide all information about shear deformation. The stresses and foam structure for any given strain and initial cell orientation in shear bears a unique relation to a different strain and orientation in extension. Such a mapping is obtained using the assumption that the principal axes of strain and stress corotate with each other. This in turn implies that high gas fraction foams follow the Lodge-Meissner relation, i.e. the ratio of the normal-stress difference to the shear stress equals the shear strain. The spatially periodic structure of foam along with the fact that the cell centers move affinely with the bulk, makes the above assumption a justifiable one.     

轻质高强点阵材料及其力学性能研究进展

点阵材料是一种新型轻质高强材料, 同时具备形状控制、致动、能量吸收和传热等多种功能. 文章综述了点阵材料的拉伸主导型设计原则、点阵构型和制备工艺. 拉伸主导型点阵材料的比强度和比刚度明显强于一般胞元材料, 在低密度时质量效率更加突出. 根据材料的基本构型特征主要介绍了三维八角点阵以及夹层点阵材料, 比较分析了熔模铸造法和冲压折叠成型工艺的特点. 总结了研究点阵材料力学性能的理论方法和试验研究成果, 研究表明缺陷对点阵材料力学性能的影响明显小于一般胞元材料. 对点阵材料在形状控制与致动、传热和数值计算方面的应用研究成果进行了介绍. 文中归纳了作者近期在炭纤维点阵复合材料方面的工作, 给出了制备炭纤维隐身点阵格栅的探索性工作. 主要包括炭纤维点阵复合材料的三维编织工艺和二维点阵格栅的嵌锁工艺以及隐身点阵格栅反射率试验测试结果.      

Compressive response of open-cell foams. Part I: Morphology and elastic properties

This study is concerned with the understanding and modeling of the compressive response of open cell foams. The response starts with a nearly linear elastic regime which terminates into a limit load followed by an extensive load plateau. The plateau, which is responsible for the excellent energy absorption capacity of foams, is followed by a second stiff branch. Results from polyester urethane open cell foams with relative densities of about 0.025 are used to illustrate this behavior using experiments coupled with several levels of modeling. The experiments include characterization of the microstructure and the properties of the base material and measurement of the compressive response of the foams of various cell sizes.A sequence of models for predicting the complete response of such foam is developed. The foam is idealized to be periodic using the space-filling Kelvin cell assigned the major geometric characteristics found in the foams tested. The cells are elongated in the rise direction, the ligaments are assumed to be straight, to have Plateau border cross-sections and nonuniform cross-sectional area distribution. The ligaments are modeled as shear-deformable extensional beams and the base material is assumed to be linearly elastic. Prediction of the initial elastic moduli are addressed in Part I. Closed form expressions for the material constants are presented as well as results using a FE model of the characteristic cell. Comparison between measurements and predictions is very favorable. The paper finishes with results from a limited parametric study of the elastic moduli. The results demonstrate that inclusion of the geometric complexities mentioned above is essential for successful prediction of the moduli of such foams. The nonlinear parts of the response including the foam crushing behavior are addressed in Part II.     

Controlled foam generation using cyclic diphasic flows through a constriction

Numerous industrial and academic applications of liquid foams require a fine control over their bubble size distribution and their liquid content. A particular challenge remains the generation of foams with very small bubbles and low liquid content. A simple technique which fulfils these different criteria, the “double-syringe technique”, has been exploited for decades in hospital applications. In this technique, the foaming liquid and gas are pushed repeatedly back and forth through the constriction that connects two syringes. After having motorised the technique we investigate here the influence of the different processing conditions on the obtained foam properties in a quantitative manner. We show that this technique is unique in producing foams with the same characteristic bubble size distributions over a wide range of processing conditions (tubing, fluid velocities,...), making it an ideal tool for controlled foam generation. In contrast to other techniques, the liquid fraction in the double-syringe technique can be varied without impacting the bubble size distribution. Using high-speed imaging we show that bubbles are dispersed in the aqueous phase at two different places in the device via a hitherto unreported fragmentation mechanism. We put in evidence that the obtained bubble size distributions are largely independent of most processing parameters with the exception of the geometry of the constriction and the foam formulation. We put forward a first analysis of the non-dimensional numbers of the flow and compare our results with bubbles size distributions obtained from fragmentation processes. Future work on simplified model systems is required to explain the observed mechanisms.     

Geometrical modelling of foam structures using implicit functions

Mechanical, thermo-mechanical, and fluid dynamic simulations of open-cell foams require an accurate geometry model. Usually, models are derived from computer- tomography (CT) data which do not allow analysing systematically variation and optimisation of the geometry. On the other hand, entirely computer generated models are mostly assembled of primitive objects like cylinders. This disregards strut thickness variations and node rounding which are observed in real open-cell foams. This paper presents an approach to generate models of ceramic open-cell foams using simple objects with variable thickness generated by implicit functions. This approach can also account for cavities within struts and nodes, which are observed in many real foam structures. The specific rounding at the foam nodes can be modelled by applying the transformation of Blinn. The quality of the generated foam models is verified using CT data of real foams.     

基于十四面体模型的闭孔泡沫材料动态力学性能的有限元分析

应用有限元方法分析了基于十四面体模型的三维闭孔泡沫材料的动态力学性能。计算中所有十四面体具有相同的尺寸,主要研究了不同初始冲击速度、不同相对密度以及组成泡沫的机体材料的应变强化对泡沫材料的变形模态、平台力及密实化应变能的影响,尽可能全面地描述了泡沫材料的能量吸收特性。数值结果表明:冲击速度对泡沫模型的模态影响较大,特别受到高速冲击时,冲击端泡沫形成I形然后向支撑端传播;相对密度对能量吸收能力的贡献较大,密实化应变能随相对密度呈二次曲线变化;冲击速度、相对密度及机体材料的应变强化分别与坪应力呈线性关系。     

Material degradation due to moisture and temperature. Part 1: mathematical model,analysis, and analytical solutions

The mechanical response, serviceability, and load-bearing capacity of materials and structural components can be adversely affected due to external stimuli, which include exposure to a corrosive chemical species, high temperatures, temperature fluctuations (i.e., freezing–thawing), cyclic mechanical loading, just to name a few. It is, therefore, of paramount importance in several branches of engineering—ranging from aerospace engineering, civil engineering to biomedical engineering—to have a fundamental understanding of degradation of materials, as the materials in these applications are often subjected to adverse environments. As a result of recent advancements in material science, new materials such as fiber-reinforced polymers and multi-functional materials that exhibit high ductility have been developed and widely used, for example, as infrastructural materials or in medical devices (e.g., stents). The traditional small-strain approaches of modeling these materials will not be adequate. In this paper, we study degradation of materials due to an exposure to chemical species and temperature under large strain and large deformations. In the first part of our research work, we present a consistent mathematical model with firm thermodynamic underpinning. We then obtain semi-analytical solutions of several canonical problems to illustrate the nature of the quasi-static and unsteady behaviors of degrading hyperelastic solids.     

液态泡沫渗流的机理研究进展

液态泡沫是具有高度自组织结构的非平衡系统. 泡沫中的微量液体在重力与毛细管力作用下, 在由薄膜、柏拉图通道以及交汇点形成的通道网络内的流动称为泡沫渗流(foamdrainage), 它直接影响泡沫结构的稳定性. 本文从泡沫物理学角度对液态泡沫的结构首先做了简单介绍, 并对泡沫材料与多孔介质之间的区别和联系做了简单介绍. 文章分析了由泡沫渗流、气泡粗化和液膜破裂而引起的泡沫结构演化规律, 着重介绍了目前泡沫渗流研究中对柏拉图通道边界条件的处理方法、相应的渗流模型及其在一维泡沫渗流中的应用, 并对泡沫渗流实验检测手段及微重力条件下的泡沫渗流实验和理论研究做了综述.