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1.
Polymers (Basel) ; 15(24)2023 Dec 11.
Article in English | MEDLINE | ID: mdl-38139928

ABSTRACT

This study aimed to investigate the impact resistance of monolithic and laminated polycarbonate plates for windshields in motorsport applications through a coupled experimental-numerical study. Both low- and high-velocity impact tests were performed by using a drop tower and a gas gun, respectively, considering a sharp-edged projectile impacting on flat panels. The response of the polycarbonate plates was evaluated in terms of the failure mode, perforation velocity threshold, and energy absorption mechanism. The experiments allowed for the assessment and the generalization of a 3D finite element modeling approach originally developed for supersonic application based on different state-of-the-art constitutive theories, including temperature-dependent and rate-dependent von Mises plasticity coupled with ductile damage, Mie-Grüneisen equation of state, and temperature variation due to energy dissipation under adiabatic assumptions. The approach was completed with a cohesive zone model for a laminate plate and studies were performed to highlight the relevancy of different aspects of material characterization. The tests and numerical analyses performed at different velocity ranges highlight the importance of viscoplastic behavior in a polycarbonate windshield. The numerical approach showed its capability to model the different failure modes for monolithic and laminated panels and capture the perforation velocity thresholds with appreciable accuracy, which were actually found to be quite similar for the two types of panels in the test conditions considered. A numerical investigation suggests that the development of delaminations could lead to the improved energy absorption of laminated polycarbonate. To further assess the numerical model, it was used to successfully predict the penetration threshold velocity of a polycarbonate windshield subjected to a gas gun impact test.

2.
Materials (Basel) ; 15(4)2022 Feb 17.
Article in English | MEDLINE | ID: mdl-35208060

ABSTRACT

In this study, the cyclic compression and crush behavior of chiral auxetic lattice structures produced from titanium alloy (Ti6Al4V) metallic powder using electron beam melting (EBM) additive manufacturing technology is investigated numerically and experimentally. For material characterization and understanding the material behavior of EBM printed parts, tensile and three-point flexural tests were conducted. Log signals produced during the EBM process were investigated to confirm the stability of process and the health of the produced parts. Furthermore, a compressive cyclic load profile was applied to the EBM printed chiral units having two different thicknesses to track their Poisson's ratios and displacement limits under large displacements in the absence of degradation, permanent deformations and failures. Chiral units were also crushed to investigate the effect of failure and deformation mechanisms on the energy absorption characteristics. Moreover, a surface roughness study was conducted due to high surface roughness of EBM printed parts, and an equation is offered to define load-carrying effective areas to prevent misleading cross-section measurements. In compliance with the equation and tensile test results, a constitutive equation was formed and used after a selection and calibration process to verify the numerical model for optimum topology design and mechanical performance forecasting using a non-linear computational model with failure analysis. As a result, the cyclic compression and crush numerical analyses of EBM printed Ti6Al4V chiral cells were validated with the experimental results. It was shown that the constitutive equation of EBM printed as-built parts was extracted accurately considering the build orientation and surface roughness profile. Besides, the cyclic compressive and crush behavior of chiral units were investigated. The regions of the chiral units prone to prematurely fail under crush loads were determined, and deformation modes were investigated to increase the energy absorption abilities.

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