For an ideal impact energy absorber, the initial peak force should be low and the average crushing force should be high. Also, a long stroke and a stable force history are expected. The thin-walled tube under axial loads is a kind of energy absorber that can produce controlled progressive collapse during a crash. It is a promising collapse mechanism for energy absorption with demonstrated success in industry. But the conventional thin-walled tubes still have high initial peak force and force fluctuations during a crushing process. To help to achieve a better energy absorbing structure, a research work has been carried out in this thesis. The aim of the present research is to achieve an improved understanding of the crushing behaviour of thin-walled tubes under axial loads. In the study, the entire crushing process, including the initial stage of collapse, its localization and the subsequent progressive folding has been carefully investigated by experiment. The relation between the localized plastic deformation and the corresponding crushing force is built by comparing the cross section of series of specimens and their load-displacement curves, which give a deep insight of the collapse mechanism of circular thin-walled tube under axial loads. Then some trigger systems are proposed, which is proved to be a good way to reduce the initial peak force and influence the collapse behaviour. To achieve higher energy absorbing efficiency, the multi-cell thin-walled tube has been investigated. Finally, based on the analysis in this study, a new multi-cell profile which is composed of coaxial tubes with different lengths and dented grooves is proposed. The new design is proved to be a good energy absorber with low initial peak force and very high energy absorption efficiency.

The scope of this study is to establish extensive material tests to determine the mechanical properties of cellular concrete and evaluate its potential as energy absorption material against air blast load. This study includes a literature review of existing studies on cellular concrete, proportioning, and its mechanical properties, together with studies on the properties and application of other foams such as aluminium and polymer foams. It is concluded that, unlike other foam materials, there is a lack of systematic studies on the mechanical properties of cellular concrete especially for densities less than 1000 kg/m3. The survey also reviewed the existence of materials being used as a sacrificial layer against air blast load, together with the analytical models proposed to determine the parameters required to design a cladding system. As a result it was found that cellular concrete can maintain most of the properties of the cladding materials and can be applied as a new sacrificial layer against the blast load. Extensive material tests are carried out to characterise the effect of ingredients and density on material properties of cellular concrete. Based on the experimental results, an empirical model is proposed which determines the plateau and densification regime of nominal stress-strain curve of the cellular concrete with different densities. The penetration resistance of cellular concrete with different densities under truncated, conical, flat and hemi-spherical solid indenters are studied experimental. By determining the deformation mechanism of cellular concrete under indentation with application of an X-Ray tomography image system, an analytical model is proposed to determine the resistance of cellular concrete under penetration of flat indenter. Experimental closed range blast tests are performed with 1kg and 3kg C4 explosive to determine the mitigation potential of cellular concrete against air blast load. Numerical modelling of the experimental blast test is carried out using Ansys LS-DYNA to evaluate the feasibility of the numerical modelling techniques to predict the response of cellular concrete against air blast load.

Cellular materials are often used as impact/blast attenuators due to their capacity to absorb kinetic energy when compressed to large strains. For such applications, three key material properties are the crushing stress, plateau stress and densification strain. The difficulties associated with obtaining these mechanical properties from dynamic/impact tests are outlined. The results of an experimental investigation of the quasi-static and dynamic mechanical properties of two types of cellular materials are reported.The dynamic tests were carried out using Hopkinson pressure bars. Experimentally determined propagation coefficients are employed to represent both dispersion and attenuation effects as stress waves travel along the bars. Propagation coefficients were determined for 20 mm and 40 mm diameter viscoelastic PMMA pressure bars and for elastic Magnesium pressure bars. The use of the elementary wave theory is shown to give satisfactory results for frequencies of up to approximately 15 kHz, 8 kHz and 30 kHz for the 20 mm and 40 mm diameter PMMA bars and the 23 mm diameter Magnesium bars respectively. The use of low impedance, viscoelastic pressure bars is shown to be preferable for testing low density, low strength materials.The quasi-static and dynamic compressive properties of balsa wood, Rohacell-51WF and Rohacell-110WF foams are investigated along all three principal directions. The dynamic properties were investigated by performing Split Hopkinson Pressure Bar (SHPB) and Direct Impact (DI) tests. In general, the crushing stress, the plateau stress and the densification strain remain constant with increasing strain rate of the SHPB tests. However, a dynamic enhancement of the crushing stress and plateau stress was revealed for balsa wood and Rohacell-51WF. In contrast, the plateau stresses of the Rohacell-110WF specimens are lower for SHPB than quasi-static tests. From the DI tests, it is shown that compaction waves have negligible effect on the stresses during dynamic compaction of along and across the grain balsa wood at impact speeds between approximately 20-100 m/s. Alternatively, the proximal end stresses of both Rohacell-51WF and 110WF foams increase with increasing impact velocity, following the quadratic trend predicted by 'shock theory'. This indicates that compaction waves are important for the case of Rohacell foam, even at low impact velocities.

Indiana University-Purdue University Indianapolis (IUPUI) / Thin walled tubular structures are widely used in the automotive industry because of its weight to energy absorption advantage. A lot of research has been done in different cross sectional shapes and different tapered designs, with design for manufacturability in mind, to achieve high specific energy absorption. In this study a novel type of tubular structure is proposed, in which predesigned origami initiators are introduced into conventional square tubes. The crease pattern is designed to achieve extensional collapse mode which results in decreasing the initial buckling forces and at the same time acts as a fold initiator, helping to achieve a extensional collapse mode. The influence of various design parameters of the origami pattern on the mechanical properties (crushing force and deceleration) are extensively investigated using finite element modelling. Thus, showing a predictable and stable collapse behavior. This pattern can be stamped out of a thin sheet of material. The results showed that a properly designed origami pattern can consistently trigger a extensional collapse mode which can significantly lower the peak values of crushing forces and deceleration without compromising on the mean values. Also, a comparison has been made with the behavior of proposed origami pattern for extensional mode verses origami pattern with diamond fold.

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The use of composite materials in vehicle structures could reduce the weight and thereby the fuel consumption of vehicles. As the road safety of the vehicles must be ensured, it is vital that the energy absorbing capability of the composite materials are similar to or better than the commonly used steel structures. The high specific bending stiffness of sandwich structures can with advantage be used in vehicles, provided that the structural behaviour during a crash situation is well understood and possible to predict. The purpose of this thesis is to identify and if possible to describe the failure initiation and progression in in-plane compression loaded sandwich panels. An experimental study on in-plane compression loaded sandwich panels with two different material concepts was conducted. Digital speckle photography (DSP) was used to record the displacement field of one outer face-sheet surface during compression. The sandwich panels with glass fibre preimpregnated face-sheets and a polymer foam core failed due to disintegration of the face-sheets from the core, whereas the sandwich panels with sheet molding compound face-sheets and a balsa core failed in progressive end-crushing. A simple semi-empirical model was developed to describe the structural response before and after initial failure. The postfailure behaviour of in-plane compression loaded sandwich panels was studied by considering the structural behaviour of sandwich panels with edge debonds. A parametrical finite element model was used to determine the influence of different material and geometrical properties on the buckling and postbuckling failure loads. The postbuckling failure modes studied were debond crack propagation and face-sheet failure. It could be concluded that the postbuckling failure modes were mainly determined by the ratio between the fracture toughness of the face-core interface and the bending stiffness of the face-sheets. / QC 20101111

Methods to mitigate the risk posed by seismic and blast loads to structures are of high interest to researchers. Auxetic structures are a new class of metamaterials that exhibit counterintuitive negative Poisson's ratio (NPR) behavior based on their geometric configuration. Cellular auxetics are light-weight and cost-effective materials that have the potential to demonstrate high strength and resilience under axial forces. Existing research on metallic auxetics is scarce and based mostly on analytical studies. Apparent NPR behavior of auxetics has also been linked to enhanced energy absorbing potential. A pilot study was undertaken to investigate and understand auxetic behavior in tubes constructed using ductile metals commonly found in structural applications i.e. steel and aluminum. The main objective was to establish whether performance enhancements could be obtained through auxetic behavior in ductile metal tubes. In addition, any potential benefits to auxetic performance due to base material plasticity were studied. These objectives were fulfilled by conducting an experimental and analytical investigation, the results of which are presented in this thesis. The experimental program consisted of establishing a design methodology, manufacturing, and laboratory testing for tubular metallic specimens. A total of eight specimens were designed and manufactured comprising five steel and three aluminum. For each base metal, three different geometric configurations of cells were designed: one with a rectangular array of circular voids and two with void geometries based on the collapsed shape of circular cells in a design tube under uniaxial compressive stress. A parameter called the Deformation Ratio (DR) was introduced to quantify cell geometry. Designed tubes were manufactured via a six-axis laser cutting process. A custom-made test assembly was constructed and specimens were tested under reverse-cyclic uniaxial loading, with one exception. Digital Image Correlation (DIC) was used to acquire experimental strain data. The performance of the auxetic and non-auxetic tubular structures was evaluated based on the axial load-deformation characteristics, global deformations, and the specific energy absorption of the test specimens. The experimental test results confirmed that ductile metal tubes with special collapsed cell geometries were capable of demonstrating auxetic behavior under the applied elastic and inelastic uniaxial strains; both tensile and compressive. Base material plasticity was observed to have an insignificant effect on the auxetic response. Experimental results suggested that the unique deformation mechanism precipitated by the auxetic cell geometries resulted in more stable deformed shapes. Stability in global deformed shapes was observed to increase with an increase in DR value. In addition, the unique auxetic mechanism demonstrated an ability to distribute radial plastic strains uniformly over the height of the auxetic pattern. As a result, plastic strains were experienced by a greater fraction of auxetic tubes; this enhanced the energy-dissipating properties of auxetic specimens in comparison to the tested non-auxetic tubes. Tubes with cell geometries associated with higher DR values exhibited greater energy absorption relative to the non-auxetic specimen. For the same base metal, auxetic specimens exhibited greater axial strength and effective strain range, when compared to their non-auxetic counterparts. The increased strength was partially attributed to the increased cell wall thickness of the auxetic specimens. However, the increased strain range was attributed to the rotation in unit cells induced by the unique auxetic geometry. Experimental test data was used to validate the finite element (FE) and simplified macromechanical modeling approaches. These methods were adopted to develop design tools capable of replicating material performance and behavior as well as accurately predicting failure loads. Load-deformation response and effective Poisson's ratio behavior was established using FE models of as-built specimens, while simplified macromechanical equations were derived based on the equilibrium of forces to compute failure loads in tension. These equations relied on pattern geometry and measured experimental unit cell deformations. It was established that the manufacturing process had a detrimental effect on the properties of the aluminum specimens. Accordingly, empirical modifications were applied to the aluminum material model to capture this effect. FE models accurately replicated load-deformation behavior for both non-auxetic and auxetic specimens. Hence, the FE modeling approach was shown to be an effective tool for predicting material properties and response in ductile metal tubes without the need for experimental testing. The simplified strength equations also described material failure with reasonable accuracy, supporting their implementation as effective design tools to gauge tube strength. It is recommended that FE models be refined further through the addition of failure criteria and damage accumulation in material models. The result of this study established that auxetic behavior could be induced in ductile metal tubes through the introduction of unique cell geometry, thereby making them highly tunable and capable of exhibiting variable mechanical properties. Owing to their deformation mechanism and NPR behavior, auxetic tubes demonstrated geometric stability at greater deformations, which highlighted their potential for use as structural elements in systems designed to deform while bearing extreme loads e.g earthquakes and blast events. Additionally, the capability of auxetic geometries to distribute strains uniformly along their length was linked to the potential development of energy-dissipating structural components. It was suggested that new knowledge acquired in this study about auxetic behavior in ductile metals could support the development of new structural systems or methods of structural control based on NPR behavior. Finally, recommendations for future research were presented, based on the expansion of research to study the effects of multiple loading regimes and parametric changes on auxeticity as well as additional mechanical characteristics e.g shear resistance. / Master of Science / Special structures known as Auxetics have been studied that exhibit counterintuitive behavior based on their geometric configuration. The novel shapes and architecture of these structures allow them to deform such that they expand laterally in tension and contract laterally in compression; a property known as negative Poisson's ratio (NPR) which is rarely observed in naturally-occurring materials. Auxetic materials demonstrate mechanical properties such as high resilience, indentation resistance, and energy-absorption. An experimental and analytical study was undertaken to explore the beneficial properties of auxetic behavior, along with the effect of inelastic deformations in ductile metal auxetics. To this end, tubular test specimens, made with steel and aluminum, were designed and manufactured. To achieve auxetic behavior, a unique array of collapsed cells was cut out from metal tubes using a laser cutting process. Subsequently, specimens were tested in the laboratory under cyclic and monotonic loads. Experimental results indicate that tubes with auxetic geometries exhibited NPR behavior and a unique deformation mechanism based on the rotation of the unit cells. Owing to this mechanism, auxetic specimens possessed greater geometric stability under applied axial deformations, when compared to the tested non-auxetic specimens. The deformation mechanism was also responsible for a uniform distribution of strains along the length of the auxetic geometry which was linked to relatively better energy absorbing capacity than the non-auxetic tubes. Developed finite element (FE) models captured the response and behavior of all specimens with good accuracy. Derived simplified strength equations were also able to calculate the ultimate tensile failure loads for all specimens accurately. Both numerical methods demonstrated the potential to be utilized as design and evaluation tools for predicting material properties. Finally, recommendations to expand research, based on metal auxetic structures, were presented to further our understanding of auxetic behavior in ductile metals and to explore its benefits under varying loading regimes. Results from this research can be used to support the design of new structural systems or methods to control existing structures by exploiting NPR properties of ductile metal auxetics. Furthermore, energy-dissipating properties of metal auxetic materials may prove to be beneficial for structural applications under extreme loading conditions such as earthquakes and blasts.

The Rollover of heavy vehicles operating in the construction, mining and agricultural sectors is a common occurrence that may result in death or severe injury for the vehicle occupants. Safety frames called ROPS (Rollover Protective Structures) that enclose the vehicle cabin, have been used by heavy vehicle manufacturers to provide protection to vehicle occupants during rollover accidents. The design of a ROPS requires that a dual criteria be fulfilled that ensures that the ROPS has sufficient stiffness to offer protection, whilst possessing an appropriate level of flexibility to absorb some or most of the impact energy during a roll. Over the last four decades significant research has been performed on these types of safety devices which has resulted in the generation of performance standards that may be used to assess the adequacy of a ROPS design for a particular vehicle type. At present these performance standards require that destructive full scale testing methods be used to assess the adequacy of a ROPS. This method of ROPS certification can be extremely expensive given the size and weight of many vehicles that operate in these sectors. The use of analytical methods to assess the performance of a ROPS is currently prohibited by these standards. Reasons for this are attributed to a lack of available fundamental research information on the nonlinear inelastic response of safety frame structures such as this. The main aim of this project was to therefore generate fundamental research information on the nonlinear response behaviour of ROPS subjected to both static and dynamic loading conditions that could be used to contribute towards the development of an efficient analytical design procedure that may lessen the need for destructive full scale testing. In addition to this, the project also aspired to develop methods for promoting increased levels of operator safety during vehicle rollover through enhancing the level of energy absorbed by the ROPS. The methods used to fulfil these aims involved the implementation of an extensive analytical modelling program using Finite Element Analysis (FEA) in association with a detailed experimental testing program. From these studies comprehensive research information was developed on both the dynamic impact response and energy absorption capabilities of these types of structures. The established finite element models were then used to extend the investigation further and to carry out parametric studies. Important parameters such as ROPS post stiffness, rollslope inclination and impact duration were identified and their effects quantified. The final stage of the project examined the enhancement of the energy absorption capabilities of a ROPS through the incorporation of a supplementary energy absorbing device within the frame work of the ROPS. The device that was chosen for numerical evaluation was a thin walled tapered tube known as frusta that was designed to crush under a sidewards rollover and hence lessen the energy absorption demand placed upon the ROPS. The inclusion of this device was found to be beneficial in absorbing energy and enhancing the level of safety afforded to the vehicle occupants.

Finite element analysis with explicit time integration is widely used in commercial crash solvers to accurately simulate transient structural problems involving large-deformation and nonlinearity. Technological advances in computer software and hardware have expanded the boundaries of computational expense, allowing designers to analyse increasingly complex structures on desktop computers. This dissertation is a review of the use of finite element analysis for crash simulation, the principles of crashworthy design and a practical application of these methods and principles in the development of a concept energy absorber for a sailplane. Explicit nonlinear finite element analysis was used to do crash simulations of the glass, carbon and aramid fibre cockpit during the development of concept absorbers. The SOL700 solution sequence in MSC Nastran, which invokes the LS-Dyna solver for structural solution, was used. Single finite elements with Hughes-Liu shell formulation were loaded to failure in pure tension and compression and validated against material properties. Further, a simple composite crash box in a mass drop experiment was simulated and compared to experimental results. FEA was used for various crash simulations of the JS1 sailplane cockpit to determine its crashworthiness. Then, variants of a concept energy absorber with cellular aluminium sandwich construction were simulated. Two more variants constructed only of fibre-laminate materials were modelled for comparison. Energy absorption and specific energy absorption were analysed over the first 515 mm of crushing. Simulation results indicate that the existing JS1 cockpit is able to absorb energy through progressive crushing of the frontal structure without collapse of the main cockpit volume. Simulated energy absorption over the first 515 mm was improved from 2232 J for the existing structure, to 9 363 J by the addition of an energy absorber. Specific energy absorption during the simulation was increased from 1063 J/kg to 2035 J/kg. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Finite element analysis with explicit time integration is widely used in commercial crash solvers to accurately simulate transient structural problems involving large-deformation and nonlinearity. Technological advances in computer software and hardware have expanded the boundaries of computational expense, allowing designers to analyse increasingly complex structures on desktop computers. This dissertation is a review of the use of finite element analysis for crash simulation, the principles of crashworthy design and a practical application of these methods and principles in the development of a concept energy absorber for a sailplane. Explicit nonlinear finite element analysis was used to do crash simulations of the glass, carbon and aramid fibre cockpit during the development of concept absorbers. The SOL700 solution sequence in MSC Nastran, which invokes the LS-Dyna solver for structural solution, was used. Single finite elements with Hughes-Liu shell formulation were loaded to failure in pure tension and compression and validated against material properties. Further, a simple composite crash box in a mass drop experiment was simulated and compared to experimental results. FEA was used for various crash simulations of the JS1 sailplane cockpit to determine its crashworthiness. Then, variants of a concept energy absorber with cellular aluminium sandwich construction were simulated. Two more variants constructed only of fibre-laminate materials were modelled for comparison. Energy absorption and specific energy absorption were analysed over the first 515 mm of crushing. Simulation results indicate that the existing JS1 cockpit is able to absorb energy through progressive crushing of the frontal structure without collapse of the main cockpit volume. Simulated energy absorption over the first 515 mm was improved from 2232 J for the existing structure, to 9 363 J by the addition of an energy absorber. Specific energy absorption during the simulation was increased from 1063 J/kg to 2035 J/kg. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015