Optimization of the milling process for aluminum honeycomb structures

Author(s):  
Tarik Zarrouk ◽  
Mohammed Nouari ◽  
Jamal-Eddine Salhi ◽  
Hamid Makich ◽  
Merzouki Salhi ◽  
...  
2021 ◽  
Vol 164 ◽  
pp. 107785
Author(s):  
Yousef Mohamadi ◽  
Hamed Ahmadi ◽  
Omid Razmkhah ◽  
Gholamhossein Liaghat

Author(s):  
Hui Zhou ◽  
Ping Xu ◽  
Suchao Xie

The energy-absorbing structure of a crashworthy railway vehicle was designed by combining the characteristics of thin-walled metal structures and aluminum honeycomb structures: finite element models of collisions involving energy-absorbing structures were built in ANSYS/LS-DYNA. In these models, the thin-walled metal structure was modeled as a plastic kinematic hardening material, and the honeycomb structure was modeled as an equivalent solid model with orthotropic–anisotropic mechanical properties. The analysis showed that the safe velocity standard for rail vehicle collisions was improved from 25 km/h to 45 km/h by using a combined energy-absorbing structure; its energy absorption exceeded the sum of the energy absorbed by the thin-walled metal structure and honeycomb structure when loaded separately, because of the interaction effects of thin-walled metal structure and aluminum honeycomb structure. For an aluminum honeycomb to the same specification, the composite structure showed the highest SEA when using a thin-walled metal structure composed of bi-grooved tubes, followed by that using single-groove tubes: that with a straight-walled structure had the lowest SEA.


2017 ◽  
Vol 21 (4) ◽  
pp. 1224-1242 ◽  
Author(s):  
Lijun Wang ◽  
Kazuya Saito ◽  
You Gotou ◽  
Yoji Okabe

Aluminum alloy honeycomb structures were designed based on origami technology, and the specimens were fabricated by a new fabrication technology (i.e. a press and folding process). In folding process, a new folding device was successfully developed to achieve automatic fabrication of honeycomb structure. To prove the practicability of developed device, the honeycomb cores with claws were fabricated by this device, which were used to compare the mechanical properties with that bonded by common adhesive. The deformation behaviors and mechanical properties of honeycomb structures were investigated by the flatwise compressive test and three-point bending test. The load–displacement curve obtained at the room temperature showed that the load increased to a peak value and then tended rapidly to a constant. Besides, the deformation process approximately categorized into three zones, namely linear-elastic zone, plastic-plateau zone, and densification zone. The experimental results suggested that regardless of specimen type, the bending stiffness and compressive strengths were approximately 0.32 KN·m2and 0.39 MPa, respectively; revealing the bonded method by aluminum claws did not dramatically affect the mechanical properties of honeycomb structure. Moreover, the elastic deformation of honeycomb structure was numerically studied by the finite element analysis.


2020 ◽  
Vol 10 (3) ◽  
pp. 1188 ◽  
Author(s):  
Sheng Zhang ◽  
Wei Chen ◽  
Deping Gao ◽  
Liping Xiao ◽  
Longbao Han

In this paper, dynamic compression tests are developed to investigate the dynamic compression mechanical properties of the aluminum honeycomb structures at different strain rates, especially at the high strain rates. The difficulties at the high strain rates exist due to the large deformation, the low wave resistance and the size effect of the honeycomb structures. The Split Hopkinson Pressure Bar (SPHB) test method is carried out and special measures such as the adoption of waveform shaper, the size optimization of the impact bar and the specimen, and employment of the semiconductor strain gauge, etc. are taken to overcome the difficulties. It is discovered that the dynamic compression mechanical properties possess a stress hardening effect at a high strain rate from 1.3 × 103 s−1 to 2.0 × 103 s−1, but then a stress softening effect at a high strain rate of 4.6 × 103 s−1. It is also discovered that the yield strength and the average plateau stress at the strain rate of 2.0 × 103 s−1 is higher than that at the strain rate of 1.3 × 103 s−1. However, the yield strength and the average plateau stress at the strain rate of 4.6 × 103 s−1 is lower than that at the strain rate of 2.0 × 103 s−1 and 1.3 × 103 s−1, but higher than that at a quasi-static state. This indicates that the aluminum honeycomb structure is sensitive to the strain rate. Additionally, the damage mode of the aluminum honeycomb structure is plastic buckling, collapse and folding of the cell wall, which is carried out using dynamic compression tests. The folding length of the cell wall at a higher strain rate is found to be longer than that at a lower strain rate. The test results can also be used as the stress–strain curves of the honeycomb constitutive model at the high strain rates to carry out the numerical simulation of high-speed impact.


2010 ◽  
Vol 19 (1) ◽  
pp. 19-39 ◽  
Author(s):  
I. T. Lee ◽  
Y. Shi ◽  
A. M. Afsar ◽  
Y. Ochi ◽  
S. I. Bae ◽  
...  

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