In support of crashworthiness studies of composite airframes, the present study was undertaken to understand the large deflection flexural response and failure of graphite-epoxy laminated beams. The beam specimens were subjected to eccentric axial impact loads and to static eccentric axial loads, in order to assess the damage caused by impact. A geometrically and materially nonlinear analysis of the response and failure of the static test specimens is presented. The analysis employed an incremental, noniterative finite element model based on the Kantrovich method and a corotational solution technique. Width-wise effects are included by assuming specific forms of the displacements across the width, with length-wise variation introduced as a degree of freedom. This one-dimensional, 22 degree of freedom finite element accurately predicted the load-deflection and strain-deflection responses of the static test specimens. Inclusion of nonlinear material behavior was found to be important in correctly predicting load-deflection response of uniaxial materials, while inclusion of width-wise effects was determined to be more important for laminates with off-axis plies due to the existence of coupling between bending and twisting curvatures (D₁₆and D₂₆). Once material nonlinearity begins to occur in flexure, even symmetric laminates exhibit bending-stretching coupling due to different material response in tension and compression. / Master of Science

Quando ocorre uma colisão, o comportamento estrutural de veículos, componentes ou sistemas mecânicos é analisado através de um parâmetro chamado crashworthiness, conceituado como a capacidade ou habilidade de uma estrutura, ou parte dela, de absorver energia cinética (resultante de impacto) e manter o colapso sob controle, mantendo a integridade no espaço do(s) ocupante(s). Este parâmetro pode também ser determinado para outro tipo de estruturas, como por exemplo, dispositivos de armazenamento de material (containers). Esta dissertação apresenta uma revisão bibliográfica sobre crashworthiness e o comportamento de estruturas quando submetidas a ensaios de impacto. Apresentam-se conceitos, histórico, evolução e principais áreas envolvidas. Destaca-se a utilização de programas de modelamento por elementos finitos na simulação e análise de colisão. Simula-se e analisa-se o impacto de modelos simplificados de container, típicos para o armazenamento de material radioativo, em queda livre contra uma superfície rígida, utilizando o software de elementos finitos ANSYS/LS-DYNA numa análise dinâmica explícita, apresentando-se resultados e conclusões e sugestões para trabalhos futuros. / The structural behavior of a vehicle or a mechanical system during collision is a very complex event. To analyze this behavior it's necessary to submit them to crash tests. These tests are made for the determination of the structure behavior and measure the kinetic energy absorption capability of a structure produced during a collision. This parameter is known as crashworthiness. In this work it is made a bibliographical review about crashworthiness and the behavior of structures under impact tests. Also, concepts, historical, evolution and the main involved areas are presented. The use of software's of finite elements in modeling and analyze of impact tests its highlighted. The drop test of a model of container, typical to storage of radioactive waste, is performed using the software of finite element ANSYS/LS-DYNA in an explicit analysis. Results, conclusions and comments for futures works are presented.

One of the principal energy absorbing structural components that influences the crashworthiness of a vehicle is the side-rail, which is also commonly referred to as an s-rail due to its shape that is reminiscent of an “s”. To improve the crashworthiness of a vehicle, in the wake of significant environmental pressures requiring vehicle light-weighting, the parameters that govern the crash response of the s-rail and the implications of light-weight material substitution need to be better understood. In this work, the main parameters that govern the crash response of an s-rail and the variables that influence them were identified and assessed through a combined experimental and numerical modelling programme. In particular, the as-formed properties of aluminium alloy s-rails, due to the tube bending and hydroforming fabrication route were examined. Tube bending, hydroforming and crash experiments were conducted to examine and assess the effects of initial tube thickness, strength, geometry, bend severity, work hardening, thickness changes and residual stresses on the crash response of the s-rail. The forming process variables, springback, thickness, strains, and force and energy response measured in the experiments were used to validate the finite element models developed herein. The validated numerical models of tube bending, hydroforming and crash provided additional insight and also allowed further investigation of the parameters governing the crash response of s-rails. The relevant parameters governing the crash response of s-rails were isolated and the basis for a set of design guidelines, in terms of maximizing energy absorption or minimizing mass, was established. The overall size is the most influential design parameter affecting the energy absorption capability of the s-rail, followed by the initial thickness, material strength, cross-sectional geometry, bend severity and hydroforming process employed, and finally boost in bending. The most significant conclusion made based on this research is that the effects of forming history must be considered to accurately predict the crash response of the s-rail. There are additional conclusions with respect to the tube bending and hydroforming processes, as well as s-rail crash response, that will contribute to improving the design of s-rails for better crashworthiness of vehicles.

One of the principal energy absorbing structural components that influences the crashworthiness of a vehicle is the side-rail, which is also commonly referred to as an s-rail due to its shape that is reminiscent of an “s”. To improve the crashworthiness of a vehicle, in the wake of significant environmental pressures requiring vehicle light-weighting, the parameters that govern the crash response of the s-rail and the implications of light-weight material substitution need to be better understood. In this work, the main parameters that govern the crash response of an s-rail and the variables that influence them were identified and assessed through a combined experimental and numerical modelling programme. In particular, the as-formed properties of aluminium alloy s-rails, due to the tube bending and hydroforming fabrication route were examined. Tube bending, hydroforming and crash experiments were conducted to examine and assess the effects of initial tube thickness, strength, geometry, bend severity, work hardening, thickness changes and residual stresses on the crash response of the s-rail. The forming process variables, springback, thickness, strains, and force and energy response measured in the experiments were used to validate the finite element models developed herein. The validated numerical models of tube bending, hydroforming and crash provided additional insight and also allowed further investigation of the parameters governing the crash response of s-rails. The relevant parameters governing the crash response of s-rails were isolated and the basis for a set of design guidelines, in terms of maximizing energy absorption or minimizing mass, was established. The overall size is the most influential design parameter affecting the energy absorption capability of the s-rail, followed by the initial thickness, material strength, cross-sectional geometry, bend severity and hydroforming process employed, and finally boost in bending. The most significant conclusion made based on this research is that the effects of forming history must be considered to accurately predict the crash response of the s-rail. There are additional conclusions with respect to the tube bending and hydroforming processes, as well as s-rail crash response, that will contribute to improving the design of s-rails for better crashworthiness of vehicles.

Cross median crashes have become a serious problem in recent years. Most of the median cross sections used for divided highways have terrains with steep slopes. Traffic barriers, frequently used on slopes, are generally designed based on the findings obtained from crash tests performed on flat terrain. For barriers placed on roadside and median slopes, vehicle impact height varies depending on the trajectory of the vehicle along the ditch section and lateral offset of the barrier. Thus depending on the placement location on a relatively steep slope, a barrier can be impacted by an errant vehicle at height and orientation more critical compared to those considered during its design. Hence, detailed study of performance of barriers on roadside and median slopes is needed to achieve acceptable safety performance. In this study, performances of modified G4(1S) W-beam, Midwest Guardrail System (MGS), modified Thrie-beam, modified weak post W-beam, and box-beam guardrail systems on sloped terrains are investigated using numerical simulations. A procedure is developed that provide guidance for their placement on roadside and median slopes. The research approach consists of nonlinear finite element analyses and multi-rigid-body dynamic analyses approach. Detailed finite element representation for each of the barriers is developed using LS-DYNA. Model fidelity is assessed through comparison of simulated and measured responses reported in full scale crash test studies conducted on flat terrain. LS-DYNA simulations of vehicle impacts on barriers placed on flat terrain at different impact heights are performed to identify performance limits of the barriers in terms of acceptable vehicle impact heights. The performances of the barriers are evaluated following the guidelines provided in NCHRP Report 350. Multi-rigid-body dynamic analysis code, CARSIM, is used to identify trajectories of the vehicles traversing various roadside and median cross-slopes. After analyzing vehicle trajectories and barrier performance limits, a guideline has been prepared with recommendations for the placement of barriers along roadside and median slopes. This guideline is then verified and refined using the responses obtained from full-scale LS-DYNA simulations. These simulations capture the full encroachment event from departure of the vehicle off the traveled way through impact with the barrier.

Quando ocorre uma colisão, o comportamento estrutural de veículos, componentes ou sistemas mecânicos é analisado através de um parâmetro chamado crashworthiness, conceituado como a capacidade ou habilidade de uma estrutura, ou parte dela, de absorver energia cinética (resultante de impacto) e manter o colapso sob controle, mantendo a integridade no espaço do(s) ocupante(s). Este parâmetro pode também ser determinado para outro tipo de estruturas, como por exemplo, dispositivos de armazenamento de material (containers). Esta dissertação apresenta uma revisão bibliográfica sobre crashworthiness e o comportamento de estruturas quando submetidas a ensaios de impacto. Apresentam-se conceitos, histórico, evolução e principais áreas envolvidas. Destaca-se a utilização de programas de modelamento por elementos finitos na simulação e análise de colisão. Simula-se e analisa-se o impacto de modelos simplificados de container, típicos para o armazenamento de material radioativo, em queda livre contra uma superfície rígida, utilizando o software de elementos finitos ANSYS/LS-DYNA numa análise dinâmica explícita, apresentando-se resultados e conclusões e sugestões para trabalhos futuros. / The structural behavior of a vehicle or a mechanical system during collision is a very complex event. To analyze this behavior it's necessary to submit them to crash tests. These tests are made for the determination of the structure behavior and measure the kinetic energy absorption capability of a structure produced during a collision. This parameter is known as crashworthiness. In this work it is made a bibliographical review about crashworthiness and the behavior of structures under impact tests. Also, concepts, historical, evolution and the main involved areas are presented. The use of software's of finite elements in modeling and analyze of impact tests its highlighted. The drop test of a model of container, typical to storage of radioactive waste, is performed using the software of finite element ANSYS/LS-DYNA in an explicit analysis. Results, conclusions and comments for futures works are presented.

Submitted in fulfillment of the requirements for the degree of Doctor of Engineering: Mechanical Engineering, Durban University of Technology, Durban, South Africa, 2017. / The development and validation of reliable numerical modelling approaches is important for higher levels of aircraft crashworthiness performance to meet the increasing demand for occupant safety. With the use of finite element analysis (FEA), development costs and certification tests may be reduced, whilst satisfying aircraft safety requirements. The primary aim of this study was the development and implementation of an explicit nonlinear dynamic finite element based methodology for investigating the crashworthiness of a small lightweight fibre reinforced composite aircraft with occupants. The aircraft was analysed as it crashed into soft soil and the FEA software MSC Dytran was selected for this purpose. The aircraft considered for the purposes of this study was based on a typical four-seater single engine fibre-reinforced plastic composite aircraft. The definition of a survivable accident is given by Coltman [1] as: “an accident in which the forces transmitted to the occupant through his seat and restraint system do not exceed the limits of human tolerance to abrupt accelerations and in which the structure in the occupant’s immediate environment remains substantially intact to the extent that a liveable volume is provided for the occupants throughout the crash sequence”. From this definition, it was determined that the FEA models must primarily provide an assessment on the crashworthiness of the aircraft in terms of the structural integrity of the airframe to ensure a minimum safe occupant volume and the tolerance of humans to abrupt (de)accelerations. An assessment of other crashworthiness factors have been ignored in this study, such as post-crash hazards (e.g. fire) and safe egress for the occupants. Stockwell [2] performed a dynamic crash analysis of an all-composite Lear Fan aircraft impacting into concrete with the explicit nonlinear dynamic finite element code MSC Dytran. The structural response of components was qualitatively verified by comparison to experimental data such as video and still camera images. The composite fuselage materials were represented with the use of simplified isotropic elastic-plastic material models, and therefore did not account for the anisotropic properties of composite materials and the associated failure mechanisms. The occupants were represented as lumped masses; therefore occupant response could not be investigated. Malis and Splichal [3] performed a dynamic crash analysis of a composite glider impacting into a rigid surface with MSC Dytran; however further model verification was required. The 50th percentile adult male (occupant of average height and mass) Hybrid III anthropomorphic test device (ATD), also referred to as a crash test dummy, was represented in the analyses with the Articulated Total Body (ATB) model integrated within MSC Dytran. Various injury criteria of the ATB model were evaluated to determine the crashworthiness of the glider. Bossak and Kaczkowski [4] performed global dynamic crash analyses of a composite light aircraft crash landing. Representative wet soil, concrete and rigid impact terrains were modelled using Lagrangian-based finite element techniques and only the vertical velocity component of the aircraft was considered to simplify analyses. It was assumed that the previous use of only a downward vertical velocity component was a result of possible numerical instabilities which commonly occur with the use of Lagrangian solvers when considering problems with large deformations, which is a characteristic of crash analyses (i.e. the addition of a horizontal velocity component may result in severe element deformation of the soft soil terrain, resulting in premature analysis termination). Analyses of the occupant were performed in separate local models, using accelerations derived from the global analyses results. The real-time interactions between the occupant and aircraft therefore could not be investigated, which is considered a major disadvantage. Impact analyses of helicopters into water were performed by Clarke and Shen [5], and Wittlin et al. [6]. Both these papers showed promising results with the use of Eulerian-based finite element techniques to model the water. Additionally, combined horizontal and forward velocity components were assigned to the fuselages with success. It must be noted that the fuselages were modelled as rigid bodies; therefore the effect of structural failure on analyses could not be investigated. Fasanella et al. [7] performed drop tests of a composite energy absorbing fuselage section into water using Eulerian, Arbitrary Lagrange Eulerian (ALE) and Smooth Particle Hydrodynamics (SPH) meshless Lagrangian-based finite element techniques to represent water. Successful correlation between experimental and numerical data was achieved; however, structural failure could not be modelled with the Eulerian-based finite element technique due to analysis code limitations at the time. A “building block” approach was used in this study to develop accurate numerical modelling techniques prior to the implementation of the full-scale crash analyses. Once the blocks produced satisfactory results in themselves, they were then integrated in order to achieve the abovementioned primary aim of this study. The sub-components (or blocks) were the occupant (viz, FEA of the human bodies’ response to impact), (FEA of) soft soil impact and (FEA of) fibre-reinforced plastic composite structures. This approach is intuitive and provides key understanding of how each sub-component contributes to the full-scale crash analyses. Published literature was reviewed, where possible, as a basis for the development and validation of the techniques employed for each sub-component. The technique required to examine the dynamic response of an occupant with MSC Dytran, integrated with the ATB model, was demonstrated through the analysis of a sled test. The numerical results were found to be comparable to experimental results found in the literature. An Eulerian-based finite element technique was implemented for soft soil impact analyses, and its effectiveness was determined through correlation of experimental penetrometer drop test results found in the literature. An investigation into the performance of the Tsai-Wu failure criterion to capture the onset and progression of failure through the layers of fibre reinforced composite laminates was conducted for an impulsively loaded unidirectional laminate strip model. Based on the results obtained, the techniques implemented for each sub-component were deemed valid for crashworthiness applications (viz. to achieve the project aim). Full-scale crash analyses of impacts into rigid and soft soil terrains with varying aircraft impact and pitch angles were investigated. Typical limitations encountered in previously published works were overcome with the techniques presented in this study. The aircrafts’ laminate layup schedule was explicitly defined in MSC Dytran, thereby eliminating the inherent inaccuracies of using isotropic models to approximate laminated composite materials. The aircraft was assigned both horizontal and vertical velocity components instead of only a vertical component, which increased the model accuracy. Numerical instabilities, due to element distortion of the terrain when using a Lagrangian approach, were eliminated with the use of an Eulerian soft soil model (Eulerian techniques are typically used to model fluids where large deformations occur, which is a characteristic of crash analyses). Structural failure was successfully implemented by coupling Lagrangian and Eulerian solvers. The ATB model allowed for the real-time interactions between the occupant and aircraft to be investigated, unlike previously where analyses of the occupant were performed in separate local models using accelerations derived from the global analyses results. The results obtained from the crash analyses provide an indication of the forces transmitted to the occupant through the seat and restraint system, and the aircraft’s ability to provide a survivable volume throughout the crash event. The explicit nonlinear dynamic finite element based methodology was successfully implemented for investigating the crashworthiness of small lightweight composite aircraft, satisfying the primary aim of this study. Chapter 1 provides a review of fibre reinforced composite materials, the finite element method (FEM), ATDs and associated analysis codes, human tolerance limits to abrupt (de)accelerations, and crash dynamics and environment. The review of the FEM initially focuses on the fundamentals of FEA and then on the features specific to MSC Dytran as it is used throughout this study. Chapter 2 discusses the development of suitable numerical modelling techniques at the sub-component level and the implementation of these techniques within the full-scale crash analyses. Chapter 3 presents and discusses the full-scale crash analyses results for three impacts into rigid terrain and three impacts into soft soil terrain with varying aircraft pitch and impact angles. The results obtained from the crash analyses provide an indication of the forces transmitted to the occupant through the seat and restraint system, and the aircraft’s ability to provide a survivable volume throughout the crash event. Chapter 4 provides a conclusion of the work performed in this study and highlights various areas for future work. / D

Orientador: Mauro Hugo Mathias / Resumo: Este trabalho traz para a indústria aeronáutica e para a academia um método para aumentar a aderência de requisitos de segurança de cabine ao produto final da engenharia de interiores de aviões, melhorando a qualidade técnica das soluções e reduzindo ciclos de desenvolvimento para novas configurações de interiores para aviões de transporte de passageiros. A pesquisa analisa os requisitos de aeronavegabilidade de interiores aplicáveis à segurança da cabine, os aspectos de ergonomia envolvidos no design de interiores e a origem da tecnologia de segurança de cabine. É discutido um aspecto de design conhecido como usabilidade e explica por que esse conceito é relevante para o projeto cabines de avião. Também são discutidos fatores humanos, erros humanos na segurança da cabine e conceitos relevantes que projetistas precisam considerar para projetos em segurança de cabine. Considerando os aspectos acima mencionados foi desenvolvido, descrito e aplicado um método denominado Design for Cabin Safety. O método que através de específicos passos objetiva aumentar a aderência de requisitos de aeronavegabilidade aplicáveis à segurança de cabine para projeto de interiores de aviões. Subsequente ao seu desenvolvimento o método foi aplicado em testes práticos em aeronaves reais e com diferentes usuários atestando sua praticidade. Desta forma a hipótese da tese foi explicada e a principal pergunta da tese foi respondida. A pesquisa termina com resultados, discussões e conclusão sobre o desenvo... (Resumo completo, clicar acesso eletrônico abaixo) / Doutor

<p>The design of vehicle components for crashworthiness is one of the most challenging problems in the automotive industry. The safety of the occupants during a crash event relies on the energy absorption capability of vehicle structures. Therefore, the body components of a vehicle are required to be lightweight and highly integrated structures. Moreover, reducing vehicle weight is another crucial design requirement since fuel economy is directly related to the mass of a vehicle. In order to address these requirements, various design concepts for vehicle bodies have been proposed using high-strength steel and different aluminum alloys. However, the price factor has always been an obstacle to completely replace regular body steels with more advanced alloys. To this end, the integration of numerical simulation and structural optimization techniques has been widely practiced addressing these requirements. Advancements in nonlinear structural design have shown the promising potential to generate innovative, safe, and lightweight vehicle structures. In addition, the implementation of structural optimization techniques has the capability to shorten the design cycle time for new models. A reduced design cycle time can provide the automakers with an opportunity to stay ahead of their competitors. During the last few decades, enormous structural optimization methods were proposed. A vast majority of these methods use mathematical programming for optimization, a method that relies on availability sensitivity analysis of objective functions. Thus, due to the necessity of sensitivity analyses, these methods remain limited to linear (or partially nonlinear) material models under static loading conditions. In other words, these methods are no able to capture all non-linearities involved in multi-body crash simulation. As an alternative solution, heuristic approaches, which do need sensitivity analyses, have been developed to address structural optimization problems for crashworthiness. The Hybrid Cellular Automaton (HCA), as a bio-inspired algorithm, is a well-practiced heuristic method that has shown promising capabilities in the structural design for vehicle components. The HCA has been continuously developed during the last two decades and designated to solve specific structural design applications. Despite all advancements, some fundamental aspects of the algorithm are still not adequately addressed in the literature. For instance, the HCA numerically implemented as a closed-loop control system. The local controllers, which dictate the design variable updates, need parameter tuning to efficiently solve different sets of problems. Previous studies suggest that one can identify some default values for the controllers. However, still, there is no well-organized strategy to tune these parameters, and proper tuning still relies on the designer’s experience.</p> <p> </p> <p> Moreover, structures with multiple materials have now become one of the perceived necessities for the automotive industry to address vehicle design requirements such as weight, safety, and cost. However, structural design methods for crashworthiness, including the HCA, are mainly applied to binary structural design problems. Furthermore, the conventional methods for the design of multi-material structures do not fully utilize the capabilities of premium materials. In other words, the development of a well-established method for the design of multi-material structures and capable of considering the cost of the materials, bonding between different materials (especially categorical materials), and manufacturing considering is still an open problem. Lastly, the HCA algorithm relies only on one hyper-parameter, the mass fraction, to synthesize structures. For a given problem, the HCA only provides one design option directed by the mass constraint. In other words, the HCA cannot tailor the dynamic response of the structure, namely, intrusion and deceleration profiles.</p> <p> </p> <p>The main objective of this dissertation is to develop new methodologies to design structures for crashworthiness applications. These methods are built upon the HCA algorithm. The first contribution is about introducing s self-tuning scheme for the controller of the algorithm. The proposed strategy eliminates the need to manually tune the controller for different problems and improve the computational performance and numerical stability. The second contribution of this dissertation is to develop a systematic approach to design multi-material crashworthy structures. To this end, the HCA algorithm is integrated with an ordered multi-material SIMP (Solid Isotropic Material with Penalization) interpolation. The proposed multi-material HCA (MMHCA) framework is a computationally efficient method since no additional design variables are introduced. The MMHCA can synthesize multi-material structures subjected to volume fraction constraints. In addition, an elemental bonding method is introduced to simulate the laser welding applied to multi-material structures. The effect of the bonding strength on the final topology designs is studied using numerical simulations. In the last step, after obtaining the multi-material designs, the HCA is implemented to remove the desired number of bonding elements and reduce the weld length.</p> <p> </p> <p>The third contribution of this dissertation is to introduce a new Cluster-based Structural Optimization method (CBSO) for the design of multi-material structures. This contribution introduces a new Cluster Validity Index with manufacturing considerations referred to as CVI_m. The proposed index can characterize the quality of the cluster in structural design considering volume fraction, size, interface as a measure of manufacturability. This multi-material structural design approach comprises three main steps: generating the conceptual design using adaptive HCA algorithm, clustering of the design domain using Multi-objective Genetic Algorithm (MOGA) optimization. In the third step, MOGA optimization is used to choose categorical materials in order to optimize the crash indicators (e.g., peak intrusion, peak contact force, load uniformity) or the cost of the raw materials. The effectiveness of the algorithm is investigated using numerical examples.</p>

In the transportation sector, crash structures are often used to protect their inhabitants inthe event of a collision. These crash structures frequently utilize thin-walled tubes as energyabsorbers. The process of developing thin-walled tubes is iterative based and requires mul-tiple simulations, making it resource intensive. This thesis researches how thin-walled tubesare developed today, what kind of challenges exist in the development process and whattools and methods are used to shorten the development lead times. Later a new methodfor assessing TWBs crashworthiness before a simulation is investigated. In this method43 cross-section geometries from thin-walled tubes used in automobiles are parameterized.These tubes are later subjected to a dynamic crash simulation along their longitudinal axis.Results from these simulations are correlated to their respective parameters in order to findmeaningful relation between the parameters and results. It was found that the circumferenceof a cross-section correlates with its crashworthiness. With this finding, the developmentlead times of thin-walled tubes could be shortened by reducing the amount of required FEMsimulations.