METHODOLOGY FOR THE DESIGN OF A LIGHTER FOAM FILLED TUBE STRUCTURE FOR IMPROVED CRASHWORTHINESS PARAMETERS SUBJECTED TO QUASI STATIC AXIAL COMPRESSION

Abstract

The objective of this research paper is to propose a general methodology for the design of a foam filled tube which is lighter and more efficient in terms of Specific Energy Absorption (SEA) and Crush Force Efficiency (CFE) than an existing square aluminium empty tube for energy absorption application. The analytical expressions are used to determine the mean load during Quasi-Static axial compression loading of the foam filled tubes. The fact the thinner tubes develop lower peak load and the higher plateau stress of the foam results in higher mean load are used in the analytical calculations. Hence, the tube thickness and the foam density are chosen as the variables. The analytical results are compared with the experimental results of the initial design to choose the best design. An FE model is used as a tool to verify and predict the characteristics of the proposed design. Finally, the experimental model of the proposed design is built and its crushing behaviour is compared against the initial design. The foam used to fill the tube is high density Polyurethane (PU) foam. The experimental validation of intermediate designs is eliminated. Thus, the time of overall design cycle is reduced.

Keywords

• Quasi-static compression
• PU Foam
• Mean load
• Specific energy absorption
• Crush force efficiency