Additive Manufacturing of Head Surrogates for Evaluation of Protection in Sports.

Head impacts are a major concern in contact sports and sports with high-speed mobility due to the prevalence of head trauma events and their dire consequences. Surrogates of human heads are required in laboratory testing to safely explore the efficacy of impact-mitigating mechanisms. This work proposes using polymer additive manufacturing technologies to obtain a substitute for the human skull to be filled with a silicone-based brain surrogate. This assembly was instrumentalized with an Inertial Measurement Unit. Its performance was compared to a standard Hybrid III head form in validation tests using commercial headgear. The tests involved impact velocities in a range centered around 5 m/s. The results show a reasonable homology between the head substitutes, with a disparity in the impact response within 20% between the proposed surrogate and the standard head form. The head surrogate herein developed can be easily adapted to other morphologies and will significantly decrease the cost of the laboratory testing of head protection equipment, all while ensuring the safety of the testing process.

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities.

Products produced by additive manufacturing (AM) seek to exploit net shape manufacturing by eliminating or minimizing post-process stages such as machining. However, many applications which include turbo machinery components with tight dimensional tolerances and a smooth surface finish will require at least a light machine finishing stage. This paper investigates the machinability of the additively fabricated INCONEL718 (IN718) alloy produced by laser melting powder bed fusion (LM-PBF) with different levels of spherical porosity in the microstructure. The literature suggests that the band width for laser energy density, which combines the various scan process parameters to obtain a low spherical type porosity in the LM-PBF IN718 alloy (~1%), has wide breadth. With the increasing laser energy density and above a threshold, there is a rapid increase in the spherical pore size. In this paper, three tube samples each with different levels of spherical porosity were fabricated by varying the laser energy density for LM-PBF of the IN718 alloy within the stable and higher energy density range and the porosity measured. A low laser energy density was avoided due to balling up, which promotes highly irregular lack of fusion defects and poor consolidation within the alloy microstructure. An orthogonal turning test instrumented, with a three-component dynamometer to measure the cutting forces, was performed on AM produced IN718 tube samples under light cut conditions to simulate a finish machining process. The orthogonal turning tests were also performed on a tube sample obtained from the wrought extruded stock. The machining process parameters, which were studied include varying the cutting speed at three levels, at a fixed feed and under dry cut conditions for a short duration to avoid the tool wear. The results obtained were discussed and a notable finding was the higher rate of built-up-edge formation on the tool tip from the AM samples with a higher porosity and especially at a higher cutting speed. The paper also discusses the mechanisms that underpin the findings.

Dynamic Behavior of Aluminum Alloy Aw 5005 Undergoing Interfacial Friction and Specimen Configuration in Split Hopkinson Pressure Bar System at High Strain Rates and Temperatures.

In this paper, experimental and numerical results of an aluminum alloy's mechanical behavior are discussed. Over a wide range of strain rates (10-4 s-1 ≤ έ ≤ 103 s-1) the influence of the loading impact, velocity and temperature on the dynamic response of the material was analyzed. The interface friction effect on the material's dynamic response is examined using a split Hopkinson pressure bar (SHPB) in a high temperature experiment using finite element analysis (FEA). The effect of different friction conditions between the specimen and the transmitted/incident bars in the SHPB system was examined using cylinder bulk specimens and cylinder plates defined with four-layer configurations. The results of these tests alongside the presented numerical simulations allow a better understanding of the phenomenon and reduces (minimizes) errors during compression tests at high and low strain rates with temperatures ranging from 21 to 300 °C.

Experimental and Numerical Study of the Thermo-Viscoplastic Behavior of NICRO 12.1 for Perforation Tests.

Dynamic impact tests using thin metal plates for ballistic characterization have received significant attention in recent years. The Johnson-Cook (J-C) model is extensively used in numerical modeling of impact and penetration in metals. The AISI (American Iron and Steel Institute) 301 steel family presents good impact behavior, excellent formability, and high corrosion resistance. Thus, NICRO (Nickel and Hard Chrome Plated Steel) 12.1 (part of the AISI 301 steel family) was chosen in this work, although parameters of the J-C model or impact results were not found in the literature. In this work, NICRO 12.1 steel plates, were characterized in ballistics with an initial impact velocity up to 200 m/s and three shape nose projectiles. The Johnson-Cook parameters for the NICRO 12.1 steel were calculated for a large range of temperatures and strain rates. Impact tests were carried out using three projectiles: conical, hemispherical, and blunt. The ballistic curves, failure mode, and maximum deformation obtained with each projectile, experimentally and numerically, were compared, and a good correlation was obtained.

Postmortem Analysis Using Different Sensors and Technologies on Aramid Composites Samples after Ballistic Impact.

This work focuses on the combination of two complementary non-destructive techniques to analyse the final deformation and internal damage induced in aramid composite plates subjected to ballistic impact. The first analysis device, a 3D scanner, allows digitalising the surface of the tested specimen. Comparing with the initial geometry, the permanent residual deformation (PBFD) can be obtained according to the impact characteristics. This is a significant parameter in armours and shielding design. The second inspection technique is based on computed tomography (CT). It allows analysing the internal state of the impacted sample, being able to detect possible delamination and fibre failure through the specimen thickness. The proposed methodology has been validated with two projectile geometries at different impact velocities, being the reaction force history on the specimen determined with piezoelectric sensors. Different loading states and induced damages were observed according to the projectile type and impact velocity. In order to validate the use of the 3D scanner, a correlation between impact velocity and damage induced in terms of permanent back face deformation has been realised for both projectiles studied. In addition, a comparison of the results obtained through this measurement method and those obtained in similar works, has been performed in the same range of impact energy. The results showed that CT is needed to analyse the internal damage of the aramid sample; however, this is a highly expensive and time-consuming method. The use of 3D scanner and piezoelectric sensors is perfectly complementary with CT and could be relevant to develop numerical models or design armours.

Numerical Modelling of Femur Fracture and Experimental Validation Using Bone Simulant.

Bone fracture pattern prediction is still a challenge and an active field of research. The main goal of this article is to present a combined methodology (experimental and numerical) for femur fracture onset analysis. Experimental work includes the characterization of the mechanical properties and fracture testing on a bone simulant. The numerical work focuses on the development of a model whose material properties are provided by the characterization tests. The fracture location and the early stages of the crack propagation are modelled using the extended finite element method and the model is validated by fracture tests developed in the experimental work. It is shown that the accuracy of the numerical results strongly depends on a proper bone behaviour characterization.

Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs.

This paper focuses on the effect of the drill geometry on the drilling of woven Carbon Fiber Reinforced Polymer composite (CFRPs). Although different geometrical effects can be considered in drilling CFRPs, the present work focuses on the influence of point angle and wear because they are the important factors influencing hole quality and machining forces. Surface quality was evaluated in terms of delamination and superficial defects. Three different point angles were tested representative of the geometries commonly used in the industry. Two wear modes were considered, being representative of the wear patterns commonly observed when drilling CFRPs: flank wear and honed cutting edge. It was found that the crossed influence of the point angle and wear were significant to the thrust force. Delamination at the hole entry and exit showed opposite trends with the change of geometry. Also, cutting parameters were checked showing the feed's dominant influence on surface damage.

Theoretical Estimation of Thermal Effects in Drilling of Woven Carbon Fiber Composite.

Carbon Fiber Reinforced Polymer (CFRPs) composites are extensively used in structural applications due to their attractive properties. Although the components are usually made near net shape, machining processes are needed to achieve dimensional tolerance and assembly requirements. Drilling is a common operation required for further mechanical joining of the components. CFRPs are vulnerable to processing induced damage; mainly delamination, fiber pull-out, and thermal degradation, drilling induced defects being one of the main causes of component rejection during manufacturing processes. Despite the importance of analyzing thermal phenomena involved in the machining of composites, only few authors have focused their attention on this problem, most of them using an experimental approach. The temperature at the workpiece could affect surface quality of the component and its measurement during processing is difficult. The estimation of the amount of heat generated during drilling is important; however, numerical modeling of drilling processes involves a high computational cost. This paper presents a combined approach to thermal analysis of composite drilling, using both an analytical estimation of heat generated during drilling and numerical modeling for heat propagation. Promising results for indirect detection of risk of thermal damage, through the measurement of thrust force and cutting torque, are obtained.