The main concern of this thesis is to propose a new inverse identification procedure applied to metal forming and machining situations, which can provide an appropriate parameters set for any elastoplastic constitutive law following J_{2} plasticity and isotropic hardening, by evaluating the correlation between the experimental and numerical responses. Firstly the identification program has been developed, which combines the Levenberg-Marquardt algorithm and the Data processing methods to optimize the constitutive parameters. In terms of experimentation, dynamic compression and tensile tests have been conducted. The final deformed shape of specimens, which relies on a post-mortem analysis, has been selected as the observation quantity. As for the numerical simulation, the numerical models of the same experimental procedure have been built with the finite element software Abaqus/Explicit in order to provide numerical responses. A numerical algorithm has been proposed for the implementation of user defined elastoplastic constitutive laws in Abaqus/Explicit.

Os aços da classe SAE 5120 são largamente utilizados para a produção de eixos e engrenagens de caixas de transmissão. As adições de nióbio e boro neste aço visam modificar a microestrutura e, consequentemente, alteram as propriedades metalúrgicas e mecânicas deste aço. Adições de nióbio ancoram o crescimento de grão austenítico, permitindo um aumento de produtividade no processamento visto que temperaturas de laminação e de tratamento térmico mais elevadas podem ser aplicadas sem que ocorra o crescimento de grão austenítico. O boro encontra-se tanto na forma solúvel como nãosolúvel nos aços. O boro solúvel aumenta a temperabilidade, devido à segregação deste elemento durante a solidificação nos contornos de grãos, retardando a nucleação da ferrita. O boro não-solúvel (combinado) também contribui para o ancoramento dos contornos de grãos austeníticos, visto que este se combina com o nitrogênio formando o BN cuja temperatura de solubilização é por volta de 1360ºC. O objetivo principal foi avaliar a cinética de transformação do aço SAE 5120 com a adição simultânea de boro e nióbio por meio da curva de transformação por resfriamento contínuo (CCT) a partir do campo austenítico (930oC). As amostras foram caracterizadas por microscopia óptica e microscopia eletrônica de varredura e por ensaios de dureza, possibilitando a construção da curva CCT para diferentes taxas de resfriamento. Na análise metalográfica observou-se a segregação de manganês e cromo da matéria-prima (estrutura bandeada) e a forte tendência de formação da bainita. Com o auxílio do programa de simulação termodinâmica computacional Thermocalc, foi possível simular as fases termodinamicamente estáveis, verificando que o boro e o nióbio formam precipitados estáveis em altas temperaturas (acima de 1150ºC), sendo os principais responsáveis pelo refino de grão. A temperabilidade e comportamento mecânico foram avaliados pelos ensaios Jominy e o ensaio de impacto Brugger, respectivamente. A influência dos elementos de liga nestes ensaios foi avaliada através de método de regressão linear por meio do software Minitab. / SAE 5120-alloyed steel is largely used to manufacture transmission gears and shafts for automotive industry. Alloying with niobium and boron is intentionally made to modify the microstructure and, consequently, promoting changes in metallurgical and mechanical proprieties. Alloying with niobium prevents austenitic grain growth (pinning effect), leading to an increase of productivity since higher rolling mill and heat treatment temperatures can be achieved. Boron can be found either soluble or insoluble in steels. Soluble B increases hardness, because it segregates to grain boundaries retarding the nucleation of ferrite. Insoluble B, on the other hand, also plays a role on avoiding austenitic grain growth due to its chemical reaction with N forming BN whose solubility temperature is around 1360ºC. The main target of this work was to evaluate the kinetics of phase transformations by continuous cooling transformation (CCT) from the austenitic field (930oC). The microstructure was analyzed by optical microscope, scanning eléctron microscope (SEM), and hardness testing, allowing building the CCT diagram with different cooling rates. It was observed by means of conventional metallography the segregation of Mn and Cr (banding) during solidification of the raw material and a strong propensity to form bainite. Using the Thermocalc software, it was possible to predict the thermodynamically stable phases, proving that boron and niobium form stable precipitates at high temperatures (above 1150ºC) responsible to decrease austenitic grain size. The hardenability and mechanical properties were investigated by Jominy and Brugger impact tests, respectively. The effect alloy adding in these tests were analyzed by linear regression in the software Minitab.

Os aços da classe SAE 5120 são largamente utilizados para a produção de eixos e engrenagens de caixas de transmissão. As adições de nióbio e boro neste aço visam modificar a microestrutura e, consequentemente, alteram as propriedades metalúrgicas e mecânicas deste aço. Adições de nióbio ancoram o crescimento de grão austenítico, permitindo um aumento de produtividade no processamento visto que temperaturas de laminação e de tratamento térmico mais elevadas podem ser aplicadas sem que ocorra o crescimento de grão austenítico. O boro encontra-se tanto na forma solúvel como nãosolúvel nos aços. O boro solúvel aumenta a temperabilidade, devido à segregação deste elemento durante a solidificação nos contornos de grãos, retardando a nucleação da ferrita. O boro não-solúvel (combinado) também contribui para o ancoramento dos contornos de grãos austeníticos, visto que este se combina com o nitrogênio formando o BN cuja temperatura de solubilização é por volta de 1360ºC. O objetivo principal foi avaliar a cinética de transformação do aço SAE 5120 com a adição simultânea de boro e nióbio por meio da curva de transformação por resfriamento contínuo (CCT) a partir do campo austenítico (930oC). As amostras foram caracterizadas por microscopia óptica e microscopia eletrônica de varredura e por ensaios de dureza, possibilitando a construção da curva CCT para diferentes taxas de resfriamento. Na análise metalográfica observou-se a segregação de manganês e cromo da matéria-prima (estrutura bandeada) e a forte tendência de formação da bainita. Com o auxílio do programa de simulação termodinâmica computacional Thermocalc, foi possível simular as fases termodinamicamente estáveis, verificando que o boro e o nióbio formam precipitados estáveis em altas temperaturas (acima de 1150ºC), sendo os principais responsáveis pelo refino de grão. A temperabilidade e comportamento mecânico foram avaliados pelos ensaios Jominy e o ensaio de impacto Brugger, respectivamente. A influência dos elementos de liga nestes ensaios foi avaliada através de método de regressão linear por meio do software Minitab. / SAE 5120-alloyed steel is largely used to manufacture transmission gears and shafts for automotive industry. Alloying with niobium and boron is intentionally made to modify the microstructure and, consequently, promoting changes in metallurgical and mechanical proprieties. Alloying with niobium prevents austenitic grain growth (pinning effect), leading to an increase of productivity since higher rolling mill and heat treatment temperatures can be achieved. Boron can be found either soluble or insoluble in steels. Soluble B increases hardness, because it segregates to grain boundaries retarding the nucleation of ferrite. Insoluble B, on the other hand, also plays a role on avoiding austenitic grain growth due to its chemical reaction with N forming BN whose solubility temperature is around 1360ºC. The main target of this work was to evaluate the kinetics of phase transformations by continuous cooling transformation (CCT) from the austenitic field (930oC). The microstructure was analyzed by optical microscope, scanning eléctron microscope (SEM), and hardness testing, allowing building the CCT diagram with different cooling rates. It was observed by means of conventional metallography the segregation of Mn and Cr (banding) during solidification of the raw material and a strong propensity to form bainite. Using the Thermocalc software, it was possible to predict the thermodynamically stable phases, proving that boron and niobium form stable precipitates at high temperatures (above 1150ºC) responsible to decrease austenitic grain size. The hardenability and mechanical properties were investigated by Jominy and Brugger impact tests, respectively. The effect alloy adding in these tests were analyzed by linear regression in the software Minitab.

As one category of energetic materials, impact-initiated reactive materials are able to release a high amount of stored chemical energy under high strain rate impact loading, and are used extensively in civil and military applications. In general, polymers are introduced as binder materials to trap the reactive metal powders inside, and also act as an oxidizing agent for the metal ingredient. Since critical attention has been paid on the metal / metal reaction, only a few types of polymer / reactive metal interactions have been studied in the literature. With the higher requirement of materials resistant to different thermal and mechanical environments, the understanding and characterization of polymer / reactive metal interactions are in great demand. In this study, PTFE (Polytetrafluoroethylene) 7A / Ti (Titanium) composites were studied under high strain rates by utilizing the Taylor impact and SHPB tests. Taylor impact tests with different impact velocities, sample dimensions and sample configurations were conducted on the composite, equipped with a high-speed camera for tracking transient images during the sudden process. SHPB and Instron tests were carried out to obtain the stress vs. strain curves of the composite under a wide range of strain rates, the result of which were also utilized for fitting the constitutive relations of the composite based on the modified Johnson-Cook strength model. Thermal analyses by DTA tests under different flow rates accompanied with XRD identification were conducted to study the reaction mechanism between PTFE 7A and Ti when only heat was provided. Numerical simulations on Taylor impact tests and microstructural deformations were also performed to validate the constitutive model built for the composite system, and to investigate the possible reaction mechanism between two components. The results obtained from the high strain rate tests, thermal analyses and numerical simulations were combined to provide a systematic study on the reaction mechanism between PTFE and Ti in the composite systems, which will be instructive for future energetic studies on other polymer / reactive metal systems.

This work has been performed at the Applied Materials ScienceDivision at The Ångström Laboratory in collaboration with SandvikMining AB. The project is part of the joint research programmeCoFree.In this work, the problem of finding an impact test method forcemented carbide rock drill inserts is considered. A suitable testmethod is required to benchmark alternative binder cemented carbidesagainst today’s cobalt based grades. The developed test method isbased on a Charpy pendulum arrangement and utilizes, as in rockdrilling, impact of cylindrical bars to achieve the high impact forcesufficient to fracture the rock drill inserts. The impact issymmetrical with two inserts facing each other, which proves to be anefficient way of damaging the inserts. To gain more informationregarding the force and pulse duration, the history of the impact isrecorded with the use of strain gauges. The measured force curvesfrom repeated tests are typically very similar, a strong indicationthat the test loads the buttons in a well-defined, repeatable way.Also, quasi-static loading of the insert is present in the impactwhich agrees to the results from a static compression test. Thisindicates that the inserts are subjected to quasi-static loading,rather than dynamic loading.A single impact test procedure was developed in this work. Thismethodology proved capable of differentiating the impact performanceof two different button cemented carbide grades. Hence, the test canbe used in the future as a benchmark test. It is however necessary toobtain statistical evidence. The impact performance was measured byobserving cracks produced in the impact contact zone with the aid ofan optical microscope with 85x objective. Radial cracks are veryoften found, often forming a cross around the contact zone. Whenlarge button chippings occur due to the impact loading, a very clearsudden drop in the measured force pulse is seen. This is however notseen for impacts that only produces cracks.

As fraturas dos ossos longos são geralmente provocadas por esforços dinâmicos de impacto (choque). O esclarecimento do comportamento de ossos submetidos a testes controlados de impacto pode representar um aprofundamento no conhecimento geral sobre as questões que envolvem a ocorrência das fraturas. Os testes de impacto são, de modo geral, realizados por meio de uma máquina especificamente desenvolvida, provida de um martelo pendular que incide sobre corpos de prova do material testado. Porém, as máquinas de impacto disponíveis no mercado são projetadas para ensaiar materiais com dimensões definidas de acordo com a norma relativa ao tipo de material, que não são adaptadas para materiais biológicos. Os materiais biológicos são em geral anisotrópicos, o que impede a confecção de corpos de prova com formas e dimensões rigorosamente padronizadas, como acontece com os materiais não biológicos. Desta forma, uma máquina de ensaio de impacto para materiais biológicos deve ser, necessariamente, especificamente desenvolvida para essa finalidade, com a principal característica de que os apoios dos corpos de prova possam ser mudados de forma e posição conforme as necessidades de cada material em teste. Foi o objetivo deste trabalho, projetar, construir e testar, comparativamente a outra máquina comercialmente disponível, uma máquina de ensaio de impacto especificamente destinada a materiais biológicos, com possibilidade de variação dos vãos entre os apoios dos corpos de prova, o que flexibiliza o ensaio de acordo com as características de cada material. / Fractures of long bones are generally caused by dynamic impact loads (shock). Studying clearing the behaviour of bones submitted to controlled impact tests may contribute to deepen the general knowledge on the phenomena involving the event of fractures. The impact tests are usually carried out with a specially designed machine, provided with a pendulum hammer which strikes on specimens of the tested material. However, the commercially available impact testing machines are designed for isotropic materials, of definite shape and dimensions according to standards specific for each material, which are not adapted for biologic materials. The biologic materials are in general anisotropic by nature, what prevents the construction of test pieces with rigorously standardised shape and dimensions, as it happens with non-biological materials. Therefore, especially designed impact testing machine should be developed for this purpose. lts a main characteristic would be that the test pieces supports can be changed and moved, to adapt to their shapes and dimensions. The design, development and test of as impact testing machine specifically designed for bone, comparing it to another conmercially available machine, was the aim of this work machine developed enables the variation of the distance between the test piece supports, which allows to carry out tests according to the physical characteristics of any test piece.

The first part of the diploma thesis with name „Evaluation of dynamic damage of composite structure“ focuses on designing device for impact experiments and suitable laminate samples made from prepregs. The conditions and problems of impact tests are also demonstrated here. The second part of the thesis deals with non-destructive control of damaged specimens based on thermography. This is mainly the extent of defects in the impaired area and the evaluation of results using the pulse infrared thermography method. Finally, the relative deviation in the crack size comparison between the visual method and thermographic are compared. Consequently, the residual strength of the damaged samples against undamaged specimens are compared using bending tests.

This thesis deals with designing shape modifications of a toecap used in Honeywell brand safety shoes. The thesis shows algorithm of compression test and impact test FEA in ANSYS software. The toecap was divided into areas according to von-Misses stress. Several modifications were made in all areas separately, according to design of experiments. Best of the modifications were combined together and two best combinations selected. The goals were verified by experimental testing of manufactured toecaps. The results were even a little bit better than simulations.

Preservation and protection of the head segment is of upmost importance due to the criticality of the functions entailed in this section of the body by the brain and the nervous system. Numerous events in daily life situations such as transportation and sports pose threats of injuries that may end or change a person’s life. In the European Union, statistics report that almost 4.2 million of road users are injured non-fatally, out of which 18% is represented by motorcyclist and 40% by cyclists, being head injuries 34% for bicyclists, and 24% for two-wheeled motor vehicles. Not only vehicles, are a source of injuries for the human head according to the injury report, 6,1 million people are admitted in hospitals for sports related injuries, where sports such as hockey, swimming, cycling presented head injuries up to 28%, 25% and 16% respectively (European Association for Injury Prevention and Safety Promotion, 2013).  According to records the vast majority of head crashes result in an oblique impact (Thibault & Gennarelli, 1985). These types of impacts are characterized for involving a rotation of the head segment which is correlated with serious head injuries. Even though there is plenty of evidence suggesting the involvement of rotational forces current helmet development standards and regulations fail to recognize their importance and account only for translational impact tests. This thesis contains an evaluation for a different developed method for testing oblique impacts. In consequence a new test rig was constructed with basis on a guided free fall of a helmeted dummy head striking an oblique (angled) anvil which will induce rotation. The results obtained are intended to be subjected to a comparison with another oblique test rig that performs experiments utilizing a movable sliding plate which when impacted induces the rotation of a dropped helmeted dummy head. The outcome will solidify the presence of rotational forces at head-anvil impact and offer an alternative testing method. After setting up the new test rig; experiments were conducted utilizing bicycle helmets varying the velocities before impact from 5m/s to 6m/s crashing an angled anvil of 45°. Results showed higher peak resultant values for rotational accelerations and rotational velocities in the new test rig compared to the movable plate impact test, indicating that depending on the impact situation the “Normal Force” has a direct effect on the rotational components. On the other hand a performed finite element analysis predicted that the best correlation between both methods is when the new angled anvil impact test is submitted to crashes with a velocity before impact of 6 m/s at 45° and the movable sliding impact test to a resultant velocity vector of 7,6m/s with an angle of 30° . In conclusion the new test method is meant to provide a comparison between two different test rigs that will undoubtedly have a part in the analysis for helmet and head safety improvements.

Indiana University-Purdue University Indianapolis (IUPUI) / Traumatic Brain Injuries (TBI) are one of the most apprehensive issues today. In recent years a lot of research has been done for reducing the risk of TBI, but no concrete solution exists yet. Helmets are one of the protective devices that are used to prevent human beings from mild TBI. For many years some kind of foam has been used in helmets for energy absorption. But, in recent years non-traditional solutions other than foam are being explored by different groups. Focus of this thesis is to develop a completely new concept of energy absorption for helmet liner by diverting the impact forces in radial directions normal to the direction of impact. This work presents a new design of an advanced layered composite (ALC) for energy dissipation through action of a 3D array of compliant mechanisms. The ALC works by diverting incoming forces in multiple radial directions and also has design provisions for reducing rotational forces. Design of compliant mechanism is optimized using multi-material topology optimization algorithm considering rigid and flexible material phases together with void. The design proposed here needs to be manufactured using the advanced polyjet printing additive manufacturing process. A general and parametric design procedure is explained which can be used to produce variants of the designs for different impact conditions and different applications. Performance of the designed ALC is examined through a benchmark example in which a comparison is made between the ALC and the traditional liner foam. An impact test is carried out in this benchmark example using dynamic Finite Element Analysis in LS DYNA. The comparison parameters under consideration are gradualness of energy absorption and peak linear force transmitted from the ALC to the body in contact with it. The design in this article is done particularly for the use in sports helmets. However, the ALC may find applications in other energy absorbing structures such as vehicle crashworthy components and protective gears. The ultimate goal of this research is to provide a novel design of energy absorbing structure which reduces the risk of head injury when the helmet is worn.