EFFECT OF FORMING HISTORY ON CRASHWORTHINESS OF A SPOT-WELDED AND DOUBLE-HAT ELLIPTICAL THIN-WALLED TUBE

Year 2019, Volume: 9 Issue: 2, 275 - 285, 30.12.2019

Serkan Özel , Hüseyin Beytüt , Selçuk Karagöz

https://doi.org/10.36222/ejt.621147

Abstract

Thin-walled
structures (TWTs) are widely used in automotive and aerospace industries due to
their easy formability, high energy absorption capacity, low cost and
lightweight advantages. In this study, under dynamic axial load, the
crashworthiness of spot-welded and double-hat shaped elliptical TWT was
investigated by the finite element method (FEM). In addition, bead-shaped
trigger mechanism was added to the TWT to reduce the peak crushing force.
Changes in wall thickness (thickening or thinning of some elements), plastic
strain and work hardening may occur during forming. In order to investigate the
effect of the forming history on crashworthiness, the TWT was formed by
single-acting deep drawing using FEM and results were mapped. The results
showed that the forming history has effect on the crashworthiness of the tube.
With deep drawing results mapped to the tube, energy absorption decreased by
5.218% and peak crushing force decreased by 3.614%. RADIOSS/explicit and
nonlinear FE codes were used.

Keywords

Crashworthiness; Thin-Walled Tubes; Forming History; Finite Element Method; Deep Drawing

References

• Abramowicz, W. and N. Jones,(1984) Dynamic axial crushing of square tubes. International Journal of Impact Engineering. 2(2): p. 179-208,
• Alexander, J.M.,(1960) An approximate analysis of the collapse of thin cylindrical shells under axial loading. The Quarterly Journal of Mechanics and Applied Mathematics. 13(1): p. 10-15,
• Pugsley, A.,(1960) The large-scale crumpling of thin cylindrical columns. The Quarterly Journal of Mechanics and Applied Mathematics. 13(1): p. 1-9,
• Wierzbicki, T. and W. Abramowicz,(1983) On the Crushing Mechanics of Thin-Walled Structures. Journal of Applied Mechanics-Transactions of the Asme. 50(4a): p. 727-734,
• Li, Z.G., H.F. Yang, X.W. Hu, J.F. Wei, and Z.T. Han,(2018) Experimental study on the crush behavior and energy-absorption ability of circular magnesium thin-walled tubes and the comparison with aluminum tubes. Engineering Structures. 164: p. 1-13
• Mamalis, A.G., D.E. Manolakos, M.B. Ioannidis, P.K. Kostazos, and G. Hassiotis,(2001) Finite element simulation of the axial collapse of thin-wall square frusta. International Journal of Crashworthiness. 6(2): p. 155-164,
• Nia, A.A. and J.H. Hamedani,(2010) Comparative analysis of energy absorption and deformations of thin walled tubes with various section geometries. Thin-Walled Structures. 48(12): p. 946-954
• Sun, G.Y., Z. Wang, H. Yu, Z.H. Gong, and Q. Li,(2019) Experimental and numerical investigation into the crashworthiness of metal-foam-composite hybrid structures. Composite Structures. 209: p. 535-547, doi:10.1016/j.compstruct.2018.10.051.
• Tarlochan, F., F. Samer, A.M.S. Hamouda, S. Ramesh, and K. Khalid,(2013) Design of thin wall structures for energy absorption applications: Enhancement of crashworthiness due to axial and oblique impact forces. Thin-Walled Structures. 71: p. 7-17, doi:10.1016/j.tws.2013.04.003.
• Zheng, G., S.Z. Wu, G.Y. Sun, G.Y. Li, and Q. Li,(2014) Crushing analysis of foam-filled single and bitubal polygonal thin-walled tubes. International Journal of Mechanical Sciences. 87: p. 226-240,
• Andrews, K.R.F., G.L. England, and E. Ghani,(1983) Classification of the Axial Collapse of Cylindrical-Tubes under Quasi-Static Loading. International Journal of Mechanical Sciences. 25(9-10): p. 687-696,
• Abramowicz, W. and N. Jones,(1997) Transition from initial global bending to progressive buckling of tubes loaded statically and dynamically. International Journal of Impact Engineering. 19(5-6): p. 415-437,
• Lima, R.M., Z.N. Ismarrubie, E.S. Zainudin, and S.H. Tang,(2012) Effect of length on crashworthiness parameters and failure modes of steel and hybrid tube made by steel and GFRP under low velocity impact. International Journal of Crashworthiness. 17(3): p. 319-325,
• Estrada, Q., D. Szwedowicz, A. Rodriguez-Mendez, M. Elías-Espinosa, J. Silva-Aceves, J. Bedolla-Hernández, et al.,(2019) Effect of radial clearance and holes as crush initiators on the crashworthiness performance of bi-tubular profiles. Thin-Walled Structures. 140: p. 43-59, doi:10.1016/j.tws.2019.02.039.
• Marzbanrad, J., A. Abdollahpoor, and B. Mashadi,(2009) Effects of the triggering of circular aluminum tubes on crashworthiness. International Journal of Crashworthiness. 14(6): p. 591-599,
• Huh, H., K.P. Kim, S.H. Kim, J.H. Song, H.S. Kim, and S.K. Hong,(2003) Crashworthiness assessment of front side members in an auto-body considering the fabrication histories. International Journal of Mechanical Sciences. 45(10): p. 1645-1660,
• Karagoz, S. and A.R. Yildiz,(2017) A comparison of recent metaheuristic algorithms for crashworthiness optimisation of vehicle thin-walled tubes considering sheet metal forming effects. International Journal of Vehicle Design. 73(1-3): p. 179-188,
• Oliveira, D.A., M.J. Worswick, R. Grantab, B.W. Williams, and R. Mayer,(2006) Effect of forming process variables on the crashworthiness of aluminum alloy tubes. International Journal of Impact Engineering. 32(5): p. 826-846,
• Ma, J. and Y. Yan,(2013) Quasi‐static and dynamic experiment investigations on the crashworthiness response of composite tubes. Polymer Composites. 34(7): p. 1099-1109,
• Calladine, C. and R. English,(1984) Strain-rate and inertia effects in the collapse of two types of energy-absorbing structure. International Journal of Mechanical Sciences. 26(11-12): p. 689-701,
• Harrigan, J.J., S.R. Reid, and C. Peng,(1999) Inertia effects in impact energy absorbing materials and structures. International Journal of Impact Engineering. 22(9-10): p. 955-979,
• Karagiozova, D.,(2001) Inertia effects on some crashworthiness parameters for cylindrical shells under axial impact. International Journal of Crashworthiness. 6(4): p. 561-572,
• Johnson, G.R.,(1983) A constitutive model and data for materials subjected to large strains, high strain rates, and high temperatures. Proc. 7th Inf. Sympo. Ballistics: p. 541-547.
• Lesuer, D.R., G. Kay, and M. LeBlanc, Modeling large-strain, high-rate deformation in metals. 2001, Lawrence Livermore National Lab., CA (US).
• Kolsky, H.,(1949) An investigation of the mechanical properties of materials at very high rates of loading. Proceedings of the physical society. Section B. 62(11): p. 676,
• Zarei, H.R. and M. Kroger,(2006) Multiobjective crashworthiness optimization of circular aluminum tubes. Thin-Walled Structures. 44(3): p. 301-308
• Dutton, T., S. Iregbu, R. Sturt, A. Kellicut, B. Cowell, and K. Kavikondala,(1999) The effect of forming on the crashworthiness of vehicles with hydroformed frame siderails. SAE transactions: p. 3354-3360