Xi Liang

Creating lightweight and impact-resistant box structures has been an enduring pursuit among researchers. A new energy-absorbing structure consisting of a bionic gradient lattice-enhanced thin-walled tube is presented in this article. The gradient lattice and thin-walled tube were prepared using selective laser melting (SLM) and wire-cutting techniques, respectively. To analyze the effects of gradient pattern, mass ratio, diameter range and impact speed on structural crashworthiness, low-speed impact at 4 m/s and finite element simulation experiments were conducted. The study demonstrates that the design of inward radial gradient lattice-reinforced thin-walled tubes can effectively enhance structure’s energy-absorption efficiency and provide a more stable mode of deformation. It also shows a 17.44% specific energy-absorption advantage over the uniformly lattice-reinforced thin-walled tubes, with no significant overall gain in peak crushing force. A complex scale evaluation method was used to determine the optimum structure and the structure type with the best crashworthiness was found to be a gradient lattice-filled tube with a thickness of 0.9 mm and a slope index of 10. The gradient lattice-reinforced thin-walled tube suggested in this investigation offers guidance for designing a more efficient thin-walled energy-absorption structure.

The aim of topology optimisation is to determine the optimal distribution of material phases within the periodic cells of a microstructure. In this paper, the density of grid points under element volume fraction is constructed to replace the finite elements in the traditional SIMP framework, avoiding jagged and blurry boundaries in the computational process due to grid dependence. This is then combined with homogenisation theory, a microstructure topology optimisation algorithm with maximum bulk modulus under prescribed volume constraints is proposed, which can obtain 2D and 3D topologies with smooth boundaries. In addition, a closed form expression for the two-dimensional topological concave edge structure (taking the most typical topology as an example) was derived, and a compression experiment was conducted on the topological microstructure based on 3D metal printing technology. Scanning electron microscopy showed that the powder bonded on the surface of the printed structure was not completely melted and the step effect caused the finite element analysis results to be higher than the experimental results. Overall, the finite element simulation and experimental results of the concave surface structure have good consistency, with high strength and energy absorption effects. Topologies based on grid point density obtain microstructures with smooth boundaries, and the introduction of the Heaviside smoothing function and multiple filtering steps within this algorithm leads to more robust optimisation, facilitating 3D or 4D printing of microstructures that meet specific design requirements and confirming the feasibility of the proposed topology for lightweighting studies.

Lattice structures are characterized by a light weight, high strength, and high stiffness, and have a wide range of applications in the aerospace field. Node stress concentration is a key factor affecting the mechanical performance of lattice structures. In this paper, a new equal-strength body-centered cubic (ES-BCC) lattice structure was additively manufactured using 316L stainless steel via selective laser melting (SLM). The results of a mechanical compression test and finite element analysis revealed that the failure location of the ES-BCC structure changed from the nodes to the center of the struts. At the same density, the energy absorption, elastic modulus, and yield strength of the ES-BCC structure increased by 11.89%, 61.80%, and 53.72% compared to the BCC structure, respectively. Furthermore, the change in angle of the ES-BCC structure achieves significant changes in strength, stiffness, and energy absorption to meet different design requirements and engineering applications. The equal-strength concept design can be applied as a general design method to the design of other lightweight energy-absorbing lattice structures.

In this paper, a new hybrid structure of body-centered cubic lattice-filled thin-walled tube is designed, and the hybrid structure specimens of one-piece printing and split-printing are prepared by laser melting technique. The deformation mode and energy absorption characteristics of the new hybrid structure are investigated by experiments and numerical simulations. Under axial compression, the one-piece printed hybrid structure forms more wrinkles with smaller wavelengths, and the specific energy absorption increases by 12.14% compared with the split-printed structure; under transverse compression, the one-piece printed structure does not show the separation of the thin-walled tube from the lattice, and the specific energy absorption increases by 134.83% compared with the split-printed structure. It is worth noting that the designed hybrid structure has a 112.60% (580.15%) increase in specific energy absorption under axial compression (under transverse compression) compared to the empty tube. The effects of wall thickness, lattice density, and loading rate on the crashworthiness of the hybrid structure were investigated using a validated finite element model. This paper provides a new idea for the preparation of lightweight and high-strength energy-absorbing structures.

Based on the advantages of thin-walled tubes and lattice structures in energy absorption and improved crashworthiness, a hybrid structure of lattice-reinforced thin-walled tubes with different cross-sectional cell numbers and gradient densities was constructed, and a high crashworthiness absorber with adjustable energy absorption was proposed. The experimental and finite element characterization of the impact resistance of uniform density and gradient density hybrid tubes with different lattice arrangements to withstand axial compression was carried out to investigate the interaction mechanism between the lattice packing and the metal shell, and the energy absorption of the hybrid structure was increased by 43.40% relative to the sum of its individual components. The effect of transverse cell number configuration and gradient configuration on the impact resistance of the hybrid structure was investigated, and the results showed that the hybrid structure showed higher energy absorption than the empty tube, and the best specific energy absorption was increased by 83.02%; the transverse cell number configuration had a greater effect on the specific energy absorption of the hybrid structure with uniform density, and the maximum specific energy absorption of the hybrid structure with different configurations was increased by 48.21%. The gradient density configuration had a significant effect on the peak crushing force of the gradient structure. In addition, the effects of wall thickness, density and gradient configuration on energy absorption were quantitatively analyzed. This study provides a new idea to optimize the impact resistance of lattice-structure-filled thin-walled square tube hybrid structures under compressive loading through a combination of experiments and numerical simulations.

A category of metamaterials consisting of chiral cytosolic elements assembled periodically, in which the introduction of a rotatable annular structure gives metamaterials the ability to deform in compression–shear, has been a focus of research in recent years. In this paper, a compression–shear coupling model is developed to predict the compressive deformation behaviour of chiral metamaterials. This behaviour will be analysed by coupling the rotation of the annular node and the bending characteristics of ligament beam, which are obtained as a function of the length of ligament beam and the angle of rotation at the end of the beam. The shape function of the ligament beam under large deformation is obtained based on the elliptic integral theory; the function characterises the potential relationship between key parameters such as displacement and rotation angle at any point on the ligament beam. By simulating the deformation of cells under uniaxial compression, the reasonableness of the large deformation model of the ligament beam is verified. On this basis, a chiral cell-compression mechanical model considering the ductile deformation of the annular node is established. The compression–shear deformation of two-dimensional planar chiral metamaterials and three-dimensional cylindrical-shell chiral metamaterials was predicted; the offset displacements and torsion angles agreed with the experimental and finite element simulation results with an error of less than 10%. The developed compression–shear coupling model provides a theoretical basis for the design of chiral metamaterials, which meet the need for the precise control of shapes and properties.

Cemented particulate composite is a kind of composite material with high strength, high energy absorption, and multifunctional characteristics, which is widely used in engineering practice. The calculation of the mechanical properties of granular composites based on theoretical methods has always been a topic of discussion. A micromechanical model with a three-dimensional rigid beam-spring network (3D-RBSN) is proposed here. The stiffness matrix of the model was calculated theoretically. The model was applied to the analysis of the mechanical properties of composites material with glass beads and epoxy resin. The results indicate that the 3D-RBSN model can effectively predict the mechanical properties of composite materials, such as Young’s modulus and Poisson’s ratio. Furthermore, the damage evolution process of cemented particulate composite with initial defects was analyzed based on the 3D-RBSN model.