Browsing by Author "Tapkir, Prasad"

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    Design of a Hybrid Honeycomb Unit Cell with Enhanced In-Plane Mechanical Properties
    (SAE, 2019-04) Raeisi, Sajjad; Tapkir, Prasad; Ansari, Farha; Tovar, Andres; Mechanical and Energy Engineering, School of Engineering and Technology
    Sandwich structures with honeycomb core are widely used in the lightweight design and impact energy absorption applications in automotive, sporting, and aerospace industries. Recently, the auxetic honeycombs with negative Poisson's ratio attract substantial attention for different engineering products. In this study, we implement Additive Manufacturing technology, experimental testing, and Finite Element Analysis (FEA) to design and investigate the mechanical behavior of a novel unit cell for sandwich structure core. The new core model contains the conventional and auxetic honeycomb cells beside each other to create a Hybrid Honeycomb (HHC) for the sandwich structure. The different designs of unit cells with the same volume fraction of 15% are 3D-printed using Fused Deposition Modeling technique, and the comparative study on the mechanical behavior of conventional honeycomb, auxetic honeycomb, and HHC structures is conducted. The quasi-static uniaxial compression tests are performed on the printed samples to investigate the mechanical behavior of the printed structures. The deformation and failure modes of the different designs are studied at the cell level utilizing FEA of the compression test and experimental observation. The compressive strength of the different design is measured using three experimental tests. The new HHC unit cell design shows significantly higher mechanical properties than the auxetic and the conventional designs. Modifying the design variables of hybrid cellular core structure allows us to tailor the mechanical properties and deformation pattern in macro level to achieve the desired mechanical properties in sandwich structures.
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    Force Diverting Helmet Liner Achieved Through a Lattice of Multi-Material Compliant Mechanisms
    (ASME, 2017-08) Gokhale, Vaibhav; Tapkir, Prasad; Tovar, Andres; Mechanical Engineering, School of Engineering and Technology
    This work introduces the design of a lattice array of multi-material compliant mechanisms (LCM) that diverts the impact radial force into tangential forces through the action of elastic hinges and connecting springs. When used as the helmet liner, the LCM liner design has the potential to reduce the risk of head injury through improved impact energy attenuation. The compliant mechanism array in the liner is optimized using a multi-material topology optimization algorithm. The performance of the LCM liner design is compared with the one obtained by expanded polypropylene (EPP) foam, which is traditionally used in sport helmets. An impact test is carried out using explicit, dynamic, nonlinear finite element analysis. The parameters under consideration include the internal energy, the peak linear force, as well as von Mises stress and effective plastic strain distributions. Although there is a small increase in stress and strain values, the simulations show that the maximum internal of the LCM liner design is four times the one of the foam design while the peak linear force is reduced to about half. While the use of the LCM liner design is intended for sports helmets, this design may find application in other energy absorbing structures such as crashworthy vehicle components, blast mitigating structures, and protective gear.
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    Topology design of vehicle structures for crashworthiness using variable design time
    (2017-12) Tapkir, Prasad; Tovar, Andres; Chen, Jie; Nematollahi, Khosrow
    The passenger safety is one of the most important factors in the automotive industries. At the same time, in order to improve the overall efficiency of passenger cars, lightweight structures are preferred while designing the vehicle structures. Among various structural optimization techniques, topology optimization techniques are usually preferred to address the issue of crashworthiness. The hybrid cellular automaton (HCA) is a truly nonlinear explicit topology design method developed for obtaining conceptual designs of crashworthy vehicle components. In comparison to linear implicit methods, such as equivalent static loads, and partially nonlinear implicit methods, the HCA method fully captures all the relevant aspect of a fully nonlinear, transient dynamic crash simulation. Traditionally, the focus of the HCA method has been on designing load paths in the crash component that increase the uniform internal energy absorption ability; thus far, other relevant crashworthiness indicators such as peak crushing force and displacement have been less studied. The objective of this research is to extend the HCA method to synthesize load paths to obtain the different acceleration-displacement profiles, which allow reduced peak crushing force as well as reduced penetration during a crash event. To achieve this goal, this work introduces the concept of achieving uniform energy distribution at variable design simulation times. In the proposed work, the design time is used as a new design parameter in topology optimization. The desired volume fraction of the final design and the design time provided two dimensional design space for topology optimization, which is followed by the formulation of design of experiments (DOEs). The nonlinear analyses of the corresponding DOEs are performed using nonlinear explicit code LS-DYNA, which is followed by topology synthesis in HCA. The performance of the resulting structures showed that the short design times lead to design obtained by linear optimizers, while long simulation times lead to designs obtained by the traditional HCA method. To achieve the target crucial crash responses such as maximum acceleration and maximum displacement of the structure under the dynamic load, the geological predictor has been implemented. The concept of design time is further developed to improve structural performance of a vehicle component under the multiple loads using the method of multi-design time. Finally, the design time is implemented to generated merged designs by performing binary operations on topology-optimized designs. Numerical example of the simplified front frame is utilized to demonstrate the capabilities of the proposed approach.