Energy Absorption of Thin-Walled Square Tubes With a Prefolded Origami Pattern—Part I: Geometry and Numerical Simulation

2013 ◽  
Vol 81 (1) ◽  
Author(s):  
Jiayao Ma ◽  
Zhong You
Keyword(s):  
Numerical Simulation ◽  
Energy Absorption ◽  
Plastic Hinge ◽  
Thin Sheet ◽  
Manufacturing Cost ◽  
Developable Surface ◽  
Absorption Increase ◽  
Collapse Mode ◽  
Wide Range ◽  
Thin Walled

Thin-walled tubes subjected to axial crushing have been extensively employed as energy absorption devices in transport vehicles. Conventionally, they have a square or rectangular section, either straight or tapered. Dents are sometimes added to the surface in order to reduce the initial buckling force. This paper presents a novel thin-walled energy absorption device known as the origami crash box that is made from a thin-walled tube of square cross section whose surface is prefolded according to a developable origami pattern. The prefolded surface serves both as a type of geometric imperfection to lower the initial buckling force and as a mode inducer to trigger a collapse mode that is more efficient in terms of energy absorption. It has been found out from quasi-static numerical simulation that a new collapse mode referred to as the completed diamond mode, which features doubled traveling plastic hinge lines compared with those in conventional square tubes, can be triggered, leading to higher energy absorption and lower peak force than those of conventional ones of identical weight. A parametric study indicates that for a wide range of geometric parameters the origami crash box exhibits predictable and stable collapse behavior, with an energy absorption increase of 92.1% being achieved in the optimum case. The origami crash box can be stamped out of a thin sheet of material like conventional energy absorption devices without incurring in-plane stretching due to the developable surface of the origami pattern. The manufacturing cost is comparable to that of existing thin-walled crash boxes, but it absorbs a great deal more energy during a collision.

Ron Resch Origami Pattern Inspired Energy Absorption Structures

2018 ◽  
Vol 86 (1) ◽  
Author(s):  
Zhe Chen ◽  
Tonghao Wu ◽  
Guodong Nian ◽  
Yejie Shan ◽  
Xueya Liang ◽  
...  
Keyword(s):  
Numerical Simulations ◽  
Energy Absorption ◽  
Impact Energy ◽  
Plastic Hinge ◽  
Honeycomb Structure ◽  
Experimental Characterization ◽  
Collapse Mode ◽  
Thin Walled ◽  
Force Reduction ◽  
Absorb Impact Energy

Energy absorption structures are widely used in many scenarios. Thin-walled members have been heavily employed to absorb impact energy. This paper presents a novel, Ron Resch origami pattern inspired energy absorption structure. Experimental characterization and numerical simulations were conducted to study the energy absorption of this structure. The results show a new collapse mode in terms of energy absorption featuring multiple plastic hinge lines, which lead to the peak force reduction and larger effective stroke, as compared with the classical honeycomb structure. Overall, the Ron Resch origami-inspired structure and the classical honeycomb structure are quite complementary as energy absorption structures.

A Novel Origami Crash Box With Varying Profiles

2013 ◽  
Author(s):  
Jiayao Ma ◽  
Zhong You
Keyword(s):  
Numerical Simulation ◽  
Energy Absorption ◽  
Cross Sections ◽  
Peak Force ◽  
Geometric Imperfection ◽  
Axial Crushing ◽  
Collapse Mode ◽  
Thin Walled Tube ◽  
Thin Walled ◽  
Initial Peak

Crash boxes in automobiles are often made from thin-walled tubes. They are designed to absorb energy when subjected to axial crushing. In this paper we present a novel crash box known as the origami crash box. It is produced by pre-folding the surface of a thin-walled tube according to a developable origami pattern. The pre-folded surface serves both as a type of geometric imperfection to lower the initial peak force, and as a mode inducer to trigger a collapse mode that is more efficient in terms of energy absorption. Numerical simulation of quasi-static axial crushing of the origami crash box has shown that a new collapse mode deemed the completed diamond mode can be triggered in tubes with square, rectangular, and polygonal cross sections and tapered shapes, leading to both a substantial gain in overall energy absorption, while at the same time, a reduction in initial peak force.

Numerical Simulation of LPDC Process for Thin-Walled Aluminum Alloy

2012 ◽  
Vol 538-541 ◽  
pp. 474-478
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Manufacturing Cost ◽  
Casting Quality ◽  
Filling Ability ◽  
Low Pressure Die Casting ◽  
Thin Walled ◽  
The Cost ◽  
Pressure Die Casting ◽  
Selection Of

In general, the thin-walled casting with the thickness less than 2mm is not easy to be prepared using low-pressure die casting (LPDC) technology because of its poor filling-ability. In this paper, the LPDC process of A356 thin-walled aluminum alloy was simulated based on the selection of appropriate boundary conditions in order to save the cost. The simulation results compared with experimental results indicate the numerical simulation technology is an effective tool for reducing the manufacturing cost and improving the casting quality.

Axial Crushing of Thin-Walled Tubes With Kite-Shape Pattern

2015 ◽  
Author(s):  
Degao Hou ◽  
Yan Chen ◽  
Jiayao Ma ◽  
Zhong You
Keyword(s):  
Energy Absorption ◽  
Peak Force ◽  
Great Promise ◽  
Axial Crushing ◽  
Crushing Force ◽  
Collapse Mode ◽  
Shape Pattern ◽  
The Mean ◽  
Thin Walled ◽  
Initial Peak

Thin-walled tubes are widely used as energy absorption devices in automobiles, designed to protect the costly structures and people inside during an impact event through plastic deformation. They show excellent performance under axial loading in terms of weight efficiency, stroke distance and total energy absorption, but also have the disadvantage that the crushing force is not uniform during deformation process, especially with the existence of a high initial peak force. Recently, pattern design on tubular structures has received increasing attention. It has been found that, if the surface of a tube is pre-folded according to an origami pattern, the collapse mode of the tube can be altered, leading to changes in energy absorption performance. In this paper, we present a series of origami patterned tubes with a kite-shape pattern that is constructed by joining two pieces of Miura-ori. First of all, the geometry of the pattern is presented. We develop a theoretical model to predict the energy absorption associated with the axial crushing of the patterned tubes and derive a mathematical formula to calculate the mean crushing force accordingly. Secondly, a family of origami tubes with various profiles are designed, and their performances subjected to quasi-static axial crushing are numerically investigated. A parametric study is also conducted to establish the relationship between the pre-folded angle of the pattern and the initial peak force as well as the mean crushing force. Numerical results show that introducing patterns to thin-walled tubes offers three advantages in comparison with conventional tubes, i.e., a lower initial peak force, a more uniform crushing load, and a stable and repeatable collapse mode. A 36.0% increase in specific energy absorption and 67.2% reduction in initial peak force is achieved in the optimum case. The new origami patterned tubes show great promise as energy absorption devices.

An Upper-Bound Solution for Tube Cropping

1985 ◽  
Vol 107 (4) ◽  
pp. 365-371
Author(s):  
R. S. Rao ◽  
P. K. Wright
Keyword(s):  
Upper Bound ◽  
Plastic Hinge ◽  
Numerical Differentiation ◽  
Strain Theory ◽  
Deformation Pattern ◽  
Plastic Hinges ◽  
Bound Solution ◽  
Upper Bound Solution ◽  
Collapse Mode ◽  
Thin Walled

An upper-bound solution for the cropping of thin-walled tubes is developed, based on a plastic hinge approach, to predict the load-deflection behavior up to the point of shearing. A simple strain theory is used to estimate the deflection at the maximum cropping load. A deformation pattern (collapse mode) is proposed consisting of plastic hinges and then, for any given deflection, the associated plastic work is calculated. Subsequently, the cropping load is estimated by numerical differentiation with respect to the deflection. Comparisons are made with experiment.

scholarly journals Axial Crushing Behavior of Aluminum Square Tube with Origami Pattern

2016 ◽  
Vol 10 (2) ◽  
pp. 90 ◽  
Author(s):  
Prescilla Christy Albert ◽  
Amir Radzi Ab Ghani ◽  
Mohd Zaid Othman ◽  
Ahmad Mujahid Ahmad Zaidi
Keyword(s):  
Numerical Simulation ◽  
Energy Absorption ◽  
Testing Machine ◽  
Axial Crushing ◽  
Geometrical Shapes ◽  
Thin Walled Tube ◽  
Absorption Performance ◽  
Thin Walled ◽  
Crushing Behavior ◽  
Aluminum Alloy 6063

<span style="font-size: 10pt; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 宋体; mso-font-kerning: 1.0pt; mso-ansi-language: EN-US; mso-fareast-language: ZH-CN; mso-bidi-language: AR-SA;" lang="EN-US">The study of axial crushing behavior is important in designing crashworthy structures especially in automotive applications. The axial crushing of thin-walled tube has better energy absorption capability. Thus, introducing milled geometrical shapes on thin-walled tube may improve the energy absorption performance. The improvement of the crush response is determined through the reduction of the Initial Peak Force (IPF) and the increase of the Specific Energy Absorption (SEA). This was done by employing origami pattern milled on the surface of thin-walled square tube which was investigated experimentally and numerically. The material used for the tube was aluminum alloy 6063-T5. The simulation results were validated by experiments which were conducted using <span style="text-transform: uppercase;">Instron</span> 3382 Universal Testing Machine and <span style="text-transform: uppercase;">Instron Dynatup</span> 8250 Drop Hammer Machine. The numerical simulation then progressed by varying parameters such as dimensions and configurations of the origami pattern on the square tube. ABAQUS finite element (FE) software was used to conduct the numerical simulation. The result of employing the origami square pattern on square tube is expected to improve the crush response by lowering the IPF and increasing the SEA. The obtained results were then compared with the conventional square tube where the origami pattern on square tube enhanced the crush performance.</span>

Design of LPDC Process for Thin-Walled Casting Based on Numerical Simulation

2012 ◽  
Vol 217-219 ◽  
pp. 1786-1790
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Boundary Conditions ◽  
Process Parameters ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Simulation Technology ◽  
Thermal Boundary Conditions ◽  
Thin Walled

The LPDC process parameters of A356 thin-walled aluminum alloy were designed based on numerical simulation by precisely setting the thermal boundary conditions. By applying the designed process parameters, a sound casting with 300mm in length, 100mm in width and 1.5mm in thickness was successfully prepared. The results indicate the numerical simulation technology is an effective tool for designing casting process and reducing the manufacturing cost.

scholarly journals Spontaneous buckling of thin-walled injection-molded parts

Mechanik ◽  
2019 ◽  
Vol 92 (1) ◽  
pp. 7-9
Author(s):  
Przemysław Poszwa ◽  
Paweł Brzęk ◽  
Wiktor Hoffmann
Keyword(s):  
Numerical Simulation ◽  
Experimental Validation ◽  
Industrial Applications ◽  
Theoretical Background ◽  
Wide Range ◽  
Molded Parts ◽  
Injection Molded ◽  
Thin Walled ◽  
Plastic Parts ◽  
Injection Molded Plastic

Injection molding technology has a wide range of industrial applications, especially in packaging and casing production. In this paper the spontaneous buckling of thin-walled injection molded plastic parts was described. Theoretical background along with numerical simulation and experimental validation of this phenomenon were presented.

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