Mechanical Engineering Technology
Keith Berube, Vincent Caccese, Kathleen Elliss, Peter Howorth
With approximately 5.9 million vehicular collisions in the United States per year, the ability of a vehicle to absorb energy during a collision is critical to reducing the likelihood and severity of injuries. A primary means to absorb energy during a collision is a crush tube, which is a predominantly-prismatic-shaped, metallic structure located at the front or rear of a vehicle intended to absorb energy by progressively buckling in addition to dissipating energy, crush tubes must be light weight to reduce vehicular green-house gas emissions, resilient to fatigue, resilient to environmental exposure, and economically feasible to manufacture. Historically, these competing objectives have been satisfied via extrusion, hydroforming, or a combination of extrusion and hydroforming manufacturing processes. Such manufacturing processes limit geometric freedom, resulting in a peak initial force significantly greater than the mean force during progressive buckling. Thus, the problem, i.e., crush tubes cause an excessively large initial deceleration due the current manufacturing process. This research seeks to address this problem via two actions:
- Explore fused depositional modeling (FDM) as a possible manufacturing process for energy dissipating structures.
- Characterize the effects of FDM processing parameters and honeycomb meso-structures on energy dissipation properties (e.g., peak initial for, mean force, total energy dissipated, slope of force-deflection curve during progressive buckling). Honeycomb structures will be subjected to quasi-static, compressive forces within a design of experiments (DOE) framework.
Berube, Peter, "Effects of Process Parameters and Meso-structures on Dissipative Properties of Additively Manufactured Structures" (2021). Honors College. 648.