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TECHNICAL PAPERS

Characterization of Aluminum Honeycomb Material Failure in Large Deformation Compression, Shear, and Tearing

[+] Author and Article Information
Qing Zhou, Robert R. Mayer

Research and Development Center, General Motors Corporation, Warren, MI 48090

J. Eng. Mater. Technol 124(4), 412-420 (Sep 30, 2002) (9 pages) doi:10.1115/1.1491575 History: Received June 05, 2001; Revised December 18, 2001; Online September 30, 2002
Copyright © 2002 by ASME
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References

Gibson, L. J., and Ashby, M. F., 1997, Cellular Solids—Structure and Properties, Second Edition, Cambridge University Press.
Klintworth,  J. W., and Stronge,  W. J., 1988, “Elasto-Plastic Yield Limits and Deformation Laws for Transversely Crushed Honeycombs,” Int. J. Mech. Sci., 30, pp. 273–292.
Zhang,  J., and Ashby,  M. F., 1992, “Buckling of Honeycombs under In-Plane Biaxial Stresses,” Int. J. Mech. Sci., 34, pp. 491–509.
Wierzbicki,  T., 1983, “Crushing Analysis of Metal Honeycombs,” Int. J. Impact Eng., 1, pp. 157–174.
Zhang,  J., and Ashby,  M. F., 1992b, “The Out-of-Plane Properties of Honeycombs,” Int. J. Mech. Sci., 34, pp. 475–489.
Stronge,  W. J., and Shim,  V. P.-W., 1988, “Microdynamics of Crushing in Cellular Solids,” ASME J. Eng. Mater. Technol., 110, pp. 185–190.
Klintworth,  J. W., and Stronge,  W. J., 1989, “Plane Punch Indentation of a Ductile Honeycomb,” Int. J. Mech. Sci., 31, pp. 359–378.
Porter, J. H., 1994, “Utilizing the Crushing under Load Properties of Polypropylene and Polyethylene Honeycomb to Manage Crash Energy,” SAE-940877, International Congress & Exposition.
Mayer, R. R., and Zhou, Q., 2002. “Punch Test Simulations of Offset Deformable Barrier Honeycomb Materials,” Proc. of the 7th International LS-DYNA Users Conference, Dearborn, MI.

Figures

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Honeycomb terminology and principal directions
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Post-test Offset Deformable Barrier (ODB) used for vehicle impact test. It is made of two aluminum honeycomb materials, honeycomb block (the main block) and honeycomb bumper (flip over to the left and drop on the ground). The ODB is also covered by a thin aluminum cladding sheet.
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Compression tests in T-direction under different nominal strain-rates. (a) Honeycomb bumper material. (b) Honeycomb block material.
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A typical post-test specimen of compression in T-direction. Honeycomb cell walls collapse in buckling, bending, folding and stretching.
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Post-test specimens of in-plane compression. (a) Compression in W-direction, honeycomb cell walls take simple rotations. (b) Compression in L-direction, cell walls plastically bend and fold.
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Static in-plane compression. (a) Honeycomb bumper material. (b) Honeycomb block material.
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Test setup of double shear
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Static shear in principal directions. (a) Honeycomb bumper material. (b) Honeycomb block material. (c) Notations of shear plane direction.
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Post-test specimens of shear tests. (a) T-W shear. Failed by adhesive debonding. (b) T-L shear. Failed by sheet tearing. (c) W-L shear. Failed by sheet tearing.
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Post-test specimens of punching tests. Shown on the right are section-cut views. (a) Honeycomb bumper material. (b) Honeycomb block material.
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Punch test in T-direction with honeycomb bumper material. Square punch 50.8 mm×50.8 mm. Specimen size 100 mm×100 mm×89 mm. The calculated uniform compression curve is for the material underneath the punch.
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Punch test in T-direction with honeycomb block material. Square punch 69.9 mm×69.9 mm. Specimen size 200 mm×200 mm×101 mm. The calculated uniform compression curve is for the material underneath the punch.
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Size effect of punch test in T-direction with honeycomb block material. Square punch 88.9 mm×88.9 mm. Specimen thickness 101 mm. The calculated uniform compression curve is for the material underneath the punch.

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