Article(id=1200101376542999459, tenantId=1146029695717560320, journalId=1189645257101713411, issueId=1200101375024657125, articleNumber=null, orderNo=null, doi=10.19822/j.cnki.1671-6329.20230119, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=null, receivedDateStr=null, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1764056064973, onlineDateStr=2025-11-25, pubDate=1707062400000, pubDateStr=2024-02-05, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764056064973, onlineIssueDateStr=2025-11-25, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764056064973, creator=13701087609, updateTime=1764056064973, updator=13701087609, issue=Issue{id=1200101375024657125, tenantId=1146029695717560320, journalId=1189645257101713411, year='2024', volume='', issue='2', pageStart='1', pageEnd='62', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764056064611, creator=13701087609, updateTime=1764225105422, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200810383637344688, tenantId=1146029695717560320, journalId=1189645257101713411, issueId=1200101375024657125, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200810383637344689, tenantId=1146029695717560320, journalId=1189645257101713411, issueId=1200101375024657125, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=42, endPage=49, ext={EN=ArticleExt(id=1200101376790463396, articleId=1200101376542999459, tenantId=1146029695717560320, journalId=1189645257101713411, language=EN, title=Application and Prospect of Thin-Walled Structure in Vehicle Energy Absorbing Box, columnId=1200101375888683752, journalTitle=Automotive Digest, columnName=Special Topic on Advanced Technologies Reviews of Chongqing Jiaotong University, runingTitle=null, highlight=null, articleAbstract=

Vehicle safety performance is a primary concern for consumers when selecting a new vehicle, where the crash resistance is of utmost. Central to this is the energy absorbing box, which can dissipate impact energy through deformation and crushing mechanisms, thereby maximizing safety of passengers. To optimize the energy absorbing performance of thin-walled structure and enhance the crash protection of vehicle, the performance evaluation indicators and structural types of thin-walled energy absorbing box is analyzed,and the deformation and energy absorbing characteristic are revealed. Finally, strategies and suggestions for the future development of thin-walled energy absorbing box are proposed, aiming to provide insights for research and practice in the field of vehicle safety.

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汽车安全性能是消费者购车时的关键考量因素。其中汽车的耐撞性能尤为关键,其核心部件吸能盒可以通过变形和压溃等机制吸收冲击能量,从而更大限度地保护乘客安全。为优化薄壁结构吸能盒性能,提高车辆耐撞防护性,分析了薄壁结构吸能盒的性能评价指标及其结构类型,揭示其变形吸能特征,最后提出对未来薄壁吸能盒发展的策略和建议,旨在为汽车安全领域的研究和实践提供思路。

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李世岳(1998—),男,重庆交通大学,硕士研究生,研究方向为汽车吸能结构碰撞分析、复合材料吸能结构设计。E-mail:

胡洪林(1998—),男,重庆交通大学,硕士研究生,研究方向为汽车及智能装备碰撞安全结构设计。E-mail:

陈哲伦(1998—),男,重庆交通大学,硕士研究生,研究方向为复合材料冲击损伤分析。E-mail:

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Engineering Structures, 2020, 204: 110069., articleTitle=Crashworthiness analysis of thin-walled bio-inspired multi-cell corrugated tubes under quasi-static axial loading, refAbstract=null), Reference(id=1200151426757390447, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, doi=null, pmid=null, pmcid=null, year=2007, volume=null, issue=3, pageStart=261, pageEnd=265, url=null, language=null, rfNumber=[46], rfOrder=45, authorNames=谢中友, 李剑荣, 虞吉林, journalName=固体力学学报, refType=null, unstructuredReference=谢中友, 李剑荣, 虞吉林. 泡沫铝填充薄壁圆管的三点弯曲实验的数值模拟[J]. 固体力学学报, 2007(3): 261-265., articleTitle=泡沫铝填充薄壁圆管的三点弯曲实验的数值模拟, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1200151418079376310, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, xref=null, ext=[AuthorCompanyExt(id=1200151418087764919, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, companyId=1200151418079376310, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=School of Mechatronics and Vehicle Engineering, Chongqing Jiaotong University, Chongqing 400074), AuthorCompanyExt(id=1200151418096153529, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, companyId=1200151418079376310, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=重庆交通大学机电与车辆工程学院, 重庆 400074)])], figs=[ArticleFig(id=1200151420289774574, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, language=EN, label=null, caption=null, figureFileSmall=Q0tXZTdKBYIfTTxLBMqYMA==, figureFileBig=8ozMCU4ovpEbg4Vv9kwaRA==, tableContent=null), ArticleFig(id=1200151420394632176, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, language=CN, label=图1, caption=内嵌多边形及外界圆管薄壁结构[23]

注:T3、Q4为结构基本构型名称。

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注:a为外层菱形边长;b为内层菱形边长;h为薄壁管高度;α为菱形角度

, figureFileSmall=PU7pE8wdR229E85iAu5zvQ==, figureFileBig=xbZHQdtrGDziunrY0v13gw==, tableContent=null), ArticleFig(id=1200151420801479671, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, language=EN, label=null, caption=null, figureFileSmall=7US7IYPadOJgEHLI6of1yw==, figureFileBig=DI795knmlfK7NHbBEZjYNg==, tableContent=null), ArticleFig(id=1200151420927308792, tenantId=1146029695717560320, journalId=1189645257101713411, articleId=1200101376542999459, language=CN, label=图3, caption=仿生鹿角设计结构[28]

注:d为内径;tmax为最大壁厚;h为薄壁管高度;a为梯度厚度值。

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注:L为高度尺寸,T为外管厚度,α为冲击角度,V为冲南昌速度,A-A为填充管模截面,D为胞元边长,t为胞元厚度。

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薄壁结构在汽车吸能盒中的应用与展望
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李世岳 , 胡洪林 , 陈哲伦
汽车文摘 | 重庆交通大学前瞻技术综述专题 2024,(2): 42-49
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汽车文摘 | 重庆交通大学前瞻技术综述专题 2024, (2): 42-49
薄壁结构在汽车吸能盒中的应用与展望
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李世岳 , 胡洪林 , 陈哲伦
作者信息
  • 重庆交通大学机电与车辆工程学院, 重庆 400074
  • 李世岳(1998—),男,重庆交通大学,硕士研究生,研究方向为汽车吸能结构碰撞分析、复合材料吸能结构设计。E-mail:

    胡洪林(1998—),男,重庆交通大学,硕士研究生,研究方向为汽车及智能装备碰撞安全结构设计。E-mail:

    陈哲伦(1998—),男,重庆交通大学,硕士研究生,研究方向为复合材料冲击损伤分析。E-mail:

Application and Prospect of Thin-Walled Structure in Vehicle Energy Absorbing Box
Shiyue Li , Honglin Hu , Zhelun Chen
Affiliations
  • School of Mechatronics and Vehicle Engineering, Chongqing Jiaotong University, Chongqing 400074
出版时间: 2024-02-05 doi: 10.19822/j.cnki.1671-6329.20230119
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汽车安全性能是消费者购车时的关键考量因素。其中汽车的耐撞性能尤为关键,其核心部件吸能盒可以通过变形和压溃等机制吸收冲击能量,从而更大限度地保护乘客安全。为优化薄壁结构吸能盒性能,提高车辆耐撞防护性,分析了薄壁结构吸能盒的性能评价指标及其结构类型,揭示其变形吸能特征,最后提出对未来薄壁吸能盒发展的策略和建议,旨在为汽车安全领域的研究和实践提供思路。

薄壁结构  /  耐撞性  /  吸能特征  /  汽车安全

Vehicle safety performance is a primary concern for consumers when selecting a new vehicle, where the crash resistance is of utmost. Central to this is the energy absorbing box, which can dissipate impact energy through deformation and crushing mechanisms, thereby maximizing safety of passengers. To optimize the energy absorbing performance of thin-walled structure and enhance the crash protection of vehicle, the performance evaluation indicators and structural types of thin-walled energy absorbing box is analyzed,and the deformation and energy absorbing characteristic are revealed. Finally, strategies and suggestions for the future development of thin-walled energy absorbing box are proposed, aiming to provide insights for research and practice in the field of vehicle safety.

Thin-walled srvcture  /  Crash resistance  /  Energy absorbing characteristic  /  Vehicle safety
李世岳, 胡洪林, 陈哲伦. 薄壁结构在汽车吸能盒中的应用与展望. 汽车文摘, 2024 , (2) : 42 -49 . DOI: 10.19822/j.cnki.1671-6329.20230119
Shiyue Li, Honglin Hu, Zhelun Chen. Application and Prospect of Thin-Walled Structure in Vehicle Energy Absorbing Box[J]. Automotive Digest, 2024 , (2) : 42 -49 . DOI: 10.19822/j.cnki.1671-6329.20230119
缩略语
NHTSA National Highway Traffic Safety Administration
EA Energy Absorption
PCF Peak Collision Force
SEA Specific Energy Absorption
ACF Average Crush Force
CFE Crush Force Efficiency
汽车薄壁吸能盒本身质量小,轴向强度相对较高,能够稳定地提供轴向压缩力以抵消冲击的影响,具有良好的吸能特性[1]。作为汽车碰撞过程中的关键吸能部件,在遭受轴向冲击载荷时,前纵梁和薄壁结构吸能盒能够抵消掉大约一半的冲击动能,有效地达到保护乘车人安全的目的[2-3]
本文基于上述内容,对汽车薄壁结构的评价指标、结构类型进行全面归纳,对薄壁结构吸能特性研究现状进行阐述,最后对汽车薄壁结构未来研究方向做出了展望。
薄壁结构在受到冲击碰撞时,主要通过自身结构发生的压溃破坏变形耗散冲击负载。这个过程变化极为复杂,合理精准地评判薄壁结构的耐撞性极为重要。为了准确表征在相互作用过程中薄壁结构自身塑性对碰撞力和动能吸收能力的影响,国内外专家定义了以下主流评价指标:总吸能(Energy Absorption,EA)、最大峰值碰撞力(Peak Collision Force,PCF)、平均压溃力(Average Crush Force,ACF)、比吸能(Specific Energy Absorption,SEA)、压溃力效率(Crush Force Efficiency,CFE)[4]
薄壁结构是汽车主要吸能元件,其设计宗旨是在撞击过程中将冲击动能高效地转化为变形能,达到能量吸收的目的。EA是指在整个碰撞破坏变形当中薄壁结构耗散的所有能量,其表达式为:
$E_{\mathrm{A}}=\int_{0}^{l_{\max }} F(l) \mathrm{d} l$
式中,EA为吸能元件的EA;F为碰撞力;l为压溃位移;lmax为最大压溃位移。
在薄壁结构研究领域,PCF通常在2个关键阶段出现:一是薄壁结构在弹性极限内发生弯曲的瞬间;二是薄壁结构在碰撞过程中整体被压缩的时刻。尽管初次碰撞峰值吸能贡献较小,但其对薄壁结构整体失效具有显著影响,因此在研究碰撞问题时应将此作为研究重点。为了保证乘员安全,应尽可能减小PCF初始值,从而有效地减小碰撞加速度。
ACF是指薄壁结构受冲击压缩过程中单位压缩位移吸收的能量,其表达式为:
$F_{\mathrm{ACF}}=\frac{E_{\mathrm{a}}}{l_{\max }}$
式中,FACF为吸能元件的ACF;Ea为吸能元件的总吸能。
结合式(1)与式(2)可以看出,若lmax保持不变,EA与ACF的评价指标相同。
在碰撞过程中,SEA是指衡量材料能量吸收能力的指标,即单位质量薄壁结构所吸收的能量,其表达式为:
$S_{\mathrm{EA}}=\frac{E_{\mathrm{a}}}{M}$
式中,SEA为吸能元件的SEA;M为薄壁结构的总质量。
比吸能越大说明单位质量薄壁结构吸收能量越多,更加符合轻量化设计以及耐撞性要求。
CFE为ACF与PCF之比的百分数形式,其表达式为:
$\eta_{\mathrm{CFE}}=\frac{F_{\mathrm{ACF}}}{F_{\mathrm{PCF}}} \times 100 \%$
式中, ${\eta }_{CFE}$为吸能元件的CFE;FACF为吸能元件的ACF;FPCF为吸能元件的PCF。
综上所述,薄壁结构常用的耐撞性能评估指标主要有:EA、PCF、ACF、SEA、CFE。减小PCF有助于减小冲击加速度,提高乘员安全性。薄壁构件在冲击过程中吸收的能量越多,对乘员的保护效果越好。CFE综合考虑了EA和PCF对薄壁构件吸能特性的影响,其值越接近“1”说明薄壁结构件在碰撞吸能中变形越稳定,更加有利于乘员保护。SEA是衡量材料在能量吸收过程中效率的关键指标,应尽可能最大化SEA值以优化结构吸能特性并顺应轻量化设计趋势。理想的吸能元件应展现出较低的PCF、EA、SEA和CFE值。在薄壁吸能结构研究设计阶段,可根据具体问题和优化设计需求,选择合适的评价指标。
薄壁结构吸能盒的吸能特性与其几何尺寸、材料类型、设计结构以及载荷状态紧密相关。上世纪60年代开始,国外学者便对薄壁结构的轴向动态冲击和静态压溃进开展了大量试验研究。Alexander[5]通过试验研究薄壁圆管的轴向压溃变形过程,通过建立薄壁圆管压溃变形近似理论模型,解释了薄壁结构圆管在轴向渐进变形的吸能能力。Wierzbicki[6-7]在Alexander建立的预测模型基础上进一步提出了移动塑性铰模型,Singace[8-9]通过试验方法在二者的研究基础之上继续拓展薄壁结构受到冲击载荷时的变形特性。
不同结构类型的薄壁结构在受到冲击时表现出来的破坏形式也有所不同。国内外研究人员在Alexander研究的基础上不断地完善和揭示薄壁结构的变形破坏机制以及不同的变形模式。目前,薄壁结构理论已经取得显著的研究成果。此类结构不仅广泛应用于汽车和轨道车辆领域,而且在飞行器内部结构中也占有一席之地[10-15],下文将对单胞薄壁结构、多胞薄壁结构和泡沫填充薄壁结构3种薄壁结构吸能盒结构类型进行梳理。
单胞薄壁圆管因结构简单、能量吸收率高而备受关注。在单胞薄壁圆管结构的初始设计阶段,研究人员对其尺寸、壁厚、形状等参数进行了详细的设计研究。
Wierzbicki对薄壁结构方管的冲击压溃机制进行了研究,根据超折叠单元理论,提出了方管在对称变形模式下的平均压溃载荷理论预测模型,展示了薄壁结构的平均压溃载荷与管的长度无关,而是与管的宽度、厚度以及所使用的材料相关。Abramowicz研究发现,薄壁方管的压溃变形模式受多种因素影响,包括壁厚、长度、宽度、冲击载荷速度以及初始缺陷。此外,针对薄壁结构方管进行冲击试验,提出了与对应变率效率和有效应变距离相关的平均压溃载荷理论预测模型。
除方管及圆管之外,研究者还提出不同截面形状的单胞薄壁结构。Sun[16]对三角形薄壁结构管进行压溃试验,提出了一种可预测平均破坏应力和折叠波长的塑性模型。Ali[17]研究了五边形薄壁管和矩形薄壁管的动态压溃,展示了在相同的横截面积下,五边形薄壁管比矩形薄壁管吸能更多。Yamashita[18]通过有限元仿真探讨了管的厚度、边数及材料对多边形薄壁结构的影响,多边形薄壁结构在不超过六边的情况下,可以得到稳定的压溃变形。Nia[19]等对比了三角形、正方形、六边形和八边形截面的铝制简单多胞薄壁管进行准静态加载,结果表明,随着截面边增加多边形薄壁结构比吸能提高,吸能能力增强。除此之外,六边形和八边形截面在多晶胞结构中吸收了单位质量的最大能量。
在单胞薄壁结构中,可以通过增加单胞多边形管的边数提高其吸能效率,但其存在一定峰值,当其吸能特性达到最大值后,继续增加多边形管的边数可能会导致吸能效率降低。基于此前提下,Deng[20]提出了一种新型正弦截面横向波纹管,通过振幅、直径、波纹数量的多目标优化展示了该结构在合理波纹数和幅值下能够比传统的方管有更好的耐撞性,SEA提高53.65%。
在研究单胞薄壁结构的同时,Wierzbicki等[7]设计了设计了两胞、三胞等多胞薄壁结构,并通过超折叠单元理论预测表明了多胞薄壁结构的吸能特性优于单胞薄壁结构,自此多胞薄壁结构进入人们的视野。多胞薄壁结构通过包含不同的角单元,导致其吸能效果相比于单胞薄壁结构大幅增加。
Zhang[21]设计了一种九胞薄壁方管结构,研究发现这种结构下其包含着不同的角单元,其中十字角单元对吸能性能的增强贡献最为显著,在其结构材料不变的情况下,增加十字角单元数量能够提高其吸能特性。Najafi和Rais-Rohani[22]以方形截面的单胞薄壁结构为原型,提出了4种不同截面布置关系的多胞薄壁结构,研究结果表明,多胞薄壁结构在碰撞过程中的压溃力波动范围比单胞管小,吸能过程更加平稳。
刘亚军[23]等以正四边形多胞薄壁为基础,设计了内嵌多边形及外接圆管2种新型多胞薄壁结构(图1),利用高速摄像机记录其薄壁结构变形形式,对比发现内嵌多边形吸能效果明显高于外接圆管结构。
随着对多胞薄壁结构的深入研究,结合对自然界的观察,研究人员提出了一种基于仿生学原理的设计方法,用以指导多胞薄壁结构的设计与创新。Yin[24]发现双层多胞薄壁管可以模仿植物茎秆的结构,通过2个同心层的多边形薄壁管组合而成。仿生设计的优势在于其结构能够自然地分散载荷,使得应力分布更加均匀,从而提高其耐撞性。而且,通过对晶胞数和直径的调整,可以进一步优化其性能。试验证明,仿生双层多胞薄壁管的耐撞性比普通方管和圆管要高出很多,这种结构在轻量化设计中具有广泛应用前景。
Xu等[25]通过蒲草和竹子作为仿生模型,设计出了一种汽车前保险横梁和多胞薄壁吸能盒,经计算分析,较之普通的保险杠,其设计的仿生保险杠在较小压缩位移的条件下,显示出更高的吸能性能。
于鹏山[26]发现竹材在自然界中主要承受着风载荷和自重载荷,其和薄壁管有着相似的共同之处,通过对仿生节和仿生单元的设计,提出了一种仿生竹双层薄壁圆管(图2),分析了内管直径和壁厚等因素对新型仿竹薄壁管耐撞性和变形模式的影响,为薄壁结构仿生管提供了结构设计和尺寸优化方面的参考。
白访华[27]通过观察甲虫生理结构,设计了一种仿生八边形多胞薄壁管结构,并利用数值模拟的方法进行验证。该仿生结构相比于传统八边形多胞薄壁结构,其吸能性能至少提高了30%,同时载荷波动也有所下降,且具有更高的耐撞性。霍鹏[28]等根据鹿角骨的结构组成,提出了一种内径保持不变、外径随层数减小的仿生薄壁管,如图3所示。研究通过有限元数值模拟和试验验证,对比3种角度斜向冲击工况下该仿生薄壁管的吸能变化变化状态。结果表明,冲击变形模式会随着结构形状逐层紧缩,具有较好的吸能特性。此外,优化出梯度和厚度参数可以为车辆吸能元件的设计提供参考。
陈晓薇[29]利用方竹结构设计了仿生薄壁管的截面形状,有限元数值模拟的方式探究了不同壁厚和竹节数对仿生薄壁管耐撞性的影响。研究结果表明,该仿生薄壁管具有较好的耐撞性和变形稳定性,通过增加竹节数可以提高吸能效果和变形稳定性。此外,在增加壁厚和圆角尺寸的情况下,仿方竹结构薄壁管的最大峰值载荷以及比吸能得到了相应的提升。
牛枞[30]以雀尾螳螂虾螯为仿生原型,提出了一种正弦胞元多胞薄壁管结构,如图4所示。通过有限元数值模拟分析不同碰撞角度下仿生胞元数对薄壁管的耐撞性影响。通过计算初始峰值载荷、比吸能和碰撞力效率来验证其结构耐撞性能。结果显示,薄壁管的耐撞性能和晶胞数呈先增后减的变化趋势,当晶胞数为4时,薄壁管耐撞性处于峰值。
近年来,随着对多胞薄壁结构研究的推进以及仿生技术的发展,研究人员通过仿生工程和力学结构设计,研发出了大量的仿生多胞薄壁结构,较之传统的单胞薄壁结构,这些新颖的多胞薄壁结构在降低最大峰值载荷和提高比吸能方面都展现出更大的潜力。
研究发现,加入泡沫填充材料后薄壁结构与填充材料发生的耦合作用可以显著提高薄壁结构吸收冲击能量的能力。填充薄壁结构轴向吸能特性的研究较为广泛,常用的填充材料主要包括泡沫铝、聚氨酯泡沫和蜂窝材料[31]
泡沫铝填充薄壁结构因其优良的吸能特性受到广泛关注,国内外学者对其开展了大量的研究。发生冲击时,泡沫铝和薄壁结构管之间的相互作用表现得尤为重要,包括:泡沫从内部支撑管壁,抵抗管壁的局部屈曲;金属管对泡沫的坍塌起限制作用,延缓泡沫的失稳;泡沫铝与金属管变形的不同步产生的纵向摩擦力。这些相互作用不仅有效地解决了薄壁结构管在失效过程难以控制的问题,而且弥补了泡沫铝在单独使用时出现缺乏稳定性坍塌的不足。
泡沫铝填充薄壁结构的制备可以通过外加填充、胶结粘合、激光钎焊等方法。由于制备方法的多样性和薄壁结构设计的差异性,泡沫铝填充薄壁结构也呈现出多种形态。根据其结构类型分类,可分为泡沫铝填充单管、全填充双管、半填充四胞管等;根据其截面形状不同,可分为泡沫铝填充方管、圆管、正多边形管等[32]。钎焊泡沫铝填充薄壁方管制备流程如图5所示[33]。不同的类型的泡沫铝填充薄壁结构在吸能特性和变形机制方面展现出各自的特性。
因为泡沫铝填充薄壁结构优异的耐撞性能,国内外对其做了大量试验以及理论研究,Hanssen[34-35]通过试验讨论薄壁结构的壁厚、材料以及薄壁结构与泡沫铝之间相互作用对薄壁结构冲击变形的影响,由此基础建立泡沫填充薄壁结构的平均载荷预测模型。Seitzberger[36]通过控制变量对空管和空管薄壁结构进行轴向静压试验,探讨了不同材料、截面和尺寸大小对影响,发现在同种条件下泡沫铝填充管薄壁结构耐撞性较之空管有大幅提升。Yin[37]对不同的填充形式的泡沫铝填充薄壁方管的耐撞性能进行了探讨,发现井字形的填充方式比单层填充、双层填充以及田字填充更具吸能特性。
聚氨酯是一类由羟基化合物和异氰酸酯合成的高分子化合物,该类化合物产品展现出多样化的形态和性能特征。通过调节原材料的比例、种类以及反应温度等参数,可以实现对聚氨酯产品性能(如硬度)的调整。
聚氨酯泡沫(Polyurethane Foam,PUF)芯夹层复合材料是一种具有广泛应用前景的多功能材料,其应用范围涵盖基本的结构元素至先进的工程材料。该材料的特点包括:结构设计的简洁性、安全性、生产便捷性,同时具有优异的抗疲劳和抗冲击性能。此外,其轻质特性顺应了汽车吸能元件轻量化设计的趋势。
以聚合物泡沫作为填充材料可以提高薄壁结构的力学性能和抗冲击性,其原理是通过泡沫材料自身的压溃形变以及其与薄壁结构的交互作用提升复合结构压溃时的耐撞性能。关于聚合物泡沫填充蜂窝结构压溃性能的理论研究较少,现存的大多数研究主要以试验方式为主。丁楠等[38]通过试验对比了方形铝管、铝蜂窝填充方管、硬质聚氨酯泡沫(Rigid Polyurethane Foam, RPUF)填充方管及RPUF或铝蜂窝填充方管4种结构的轴向压溃性能,试验结果表明,采用聚合物泡沫作为填充物的薄壁结构方管在吸能效果上相较于传统的空管提高了3倍以上。
蜂窝材料因其较高的承载能力和吸能能力而被广泛应用于汽车耐撞性元件[39]制造,可以通过调节所用材料、结构及内部胞元形状、数目等参数提升蜂窝材料的吸能效果。
张勇[40]采用数值模拟和试验相结合的方法,通过改变冲击角度和速度的方式,探究不同的冲击工况下对蜂窝薄壁结构和薄壁结构空管的冲击性能影响,如图6所示,试验结果表明,任何工况下,蜂窝填充薄壁结构在冲击中的变形稳定性和吸能表现均优于薄壁空管结构。
刘颖[41]设计了一种分层递变的蜂窝薄壁结构,发现通过改变胞元半径、排列顺序以及梯度系数能够大范围改变蜂窝薄壁结构的动力响应方式,从而达到控制蜂窝材料内部应力变化范围、能量传播方向以及提高蜂窝填充薄壁结构耐撞性目的
张勇[42]通过数值模拟分析的方法探究4种胞元数不同的蜂窝填充薄壁结构在同种冲击工况下的力学变化,发现厚度对同种胞元蜂窝薄壁结构的变形模式改变不明显,同时蜂窝与薄壁空管的相互作用使得蜂窝薄壁结构抗冲击能力大幅增加。
李本怀[43]发现在薄壁空管中添加隔板与蜂窝可以使薄壁管总吸能翻倍,且因隔板与蜂窝薄壁管在冲击的过程中发生耦合作用,使其在冲击变形过程中更具稳定性。
薄壁结构作为汽车内部重要的吸能元件,其因在减震吸能、防撞抗冲击等方面的显著性能逐渐受到广泛关注,特别是其变形机制和吸能表现。研究人员主要通过轴向冲击、以及横向三点静压的试验方式探究薄壁结构的变形机理,以期为薄壁结构的优化设计和性能评估提供科学依据。
汽车发生正面碰撞时,车辆所搭载的吸能结构可以吸收60%以上的碰撞能量,因此,对薄壁结构开展轴向冲击试验尤为重要。
Zhang[44]对比分析了多种多边形截面的单胞薄壁结构,在单胞薄壁结构在轴向冲击当中主要可以发生非延展性变形、延展性变形和混合变形,其研究发现偶数边的正多边形列比奇数边的正多边形列具有更规则的折叠模式。图7为六边形截面单管的2种变形形态。
传统的多胞薄壁结构管与单胞薄壁结构变形形式大致相同,都是以渐进折叠的压溃方式吸收能量,并且折叠波段会随着多胞结构内部胞数的增加而增加,多胞薄壁波纹管的轴向冲击的模式可分为不稳定模式、钻石模式、手风琴模式和混合模式4种类型,每一模态都受到余弦波峰数及其振幅的强烈影响[45]
泡沫填充薄壁结构之间,泡沫填充材料的性质以及薄壁管的截面形状的差异会导致不同的变形模式。以泡沫铝填充薄壁结构为例,其变形模式包括:对称模式、非对称模式、混合模式及欧拉失稳模式(见图8)。
汽车发生侧面碰撞时,横向弯曲破坏是典型的破坏形态之一。车架纵梁作为重要的吸能保护元件,被广泛应用于汽车设计中,能够有效地减轻乘员受到的外部冲击力。而横向三点静压试验是一种常见的保护机制评估方法,该方法的影响因素不仅包括薄壁结构的材料属性,还涉及到结构设计、试验设置和蜂窝填充物的特性多个方面。
在横向三点静压试验中,如图9所示,尽管不同类型的薄壁结构变形过程类似,但其弯曲变形失效机制与弯曲时形成的苏醒铰接点有关。大多数变形失效均发生在塑性铰接点位置附近。研究数据表明,通过添加填充材料,薄壁圆管三点弯曲承载能力得到显著提高,并且使变形过程更稳定[46]
汽车安全性能是传统燃油汽车和新能源汽车共同面临的关键挑战。薄壁结构作为汽车关键吸能元件,其评价指标、结构特点和吸能特性一直是汽车安全研究者关注的焦点。本文通过分析薄壁结构发展现状、安全测试评价指标,发现可以从以下4个方面优化和改善薄壁结构。
(1)当前对于薄壁结构的研究主要集中于轴向正面冲击以及横向冲击,但在实际汽车碰撞事故中,冲击载荷方向往往与汽车正前方存在一定夹角,即斜侧向碰撞。这种情况下,仅考虑横向和轴向冲击,薄壁结构可能无法在斜侧向冲击中展现出其最佳性能,因此研究不同角度的斜侧向冲击碰撞对于提高薄壁结构在复杂碰撞情况下的性能具有重要意义。
(2)在多胞薄壁结构中,仿生多胞薄壁结构因其优良的耐撞特性而得到迅速迅速。然而,由于仿生结构几何复杂性,常规工艺难以加工,导致其制备成本较高,难以实现大批量生产并广泛应用于汽车制造。引用3D打印技术,为复杂几何结构的制备提供了新的可能。发展3D打印技术,有望降低制备成本同时提高生产效率。
(3)我国在泡沫填充薄壁结构设计领域中起步较晚,对不同材料的变形形式、失效机制方面的研究尚不充分。关于泡沫填充薄壁结构的数值模拟均是针对某种特定加载条件下进行,而实际面临的外界环境载荷复杂多样,需要与实际试验进行结合对比。因此,建议优化模拟预测方法,建立普适性计算模型,在提高填充薄壁结构经济性的同时扩大其实际应用范围。
(4)目前对于多胞填充薄壁结构方面探究尚不充分,建议通过调节多胞薄壁材料与填充材料之间配比关系,合理的选取多重材料的复合设计方式达到兼用不同材料优势的目的,在提升耐撞性能的同时,尽可能地实现轻量化设计以及节约制造成本。
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doi: 10.19822/j.cnki.1671-6329.20230119
  • 首发时间:2025-11-25
  • 出版时间:2024-02-05
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    重庆交通大学机电与车辆工程学院, 重庆 400074
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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