Publications

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Flexible open celled foams are commonly used for energy absorption in packaging. Over time polymers can suffer from aging by becoming stiffer and more brittle. This change in stiffness can affect the foam’s performance in a low velocity impact event. In this study, the compressive properties of new open-cell flexible polyurethane foam were compared to those obtained from aged open-cell polyurethane foam that had been in service for approximately 25 years. The foams tested had densities of 10 and 15 pcf. These low density foams provided a significant challenge to machine cylindrical compression specimens that were 1 “in height and 1” in diameter. Details of the machining process are discussed. The compressive properties obtained for both aged and new foams included testing at various strain rates (0.05. 0.10, 5 s-1) and temperatures (-54, RT, 74 °C). Results show that aging of flexible polyurethane foam does not have much of an effect on its compressive properties.

Several open-cell flexible foams, including aged polyurethane foams, were mechanically characterized over a temperature range of 40 to 20 °C. Quasi-static compression was performed to obtain the stress-strain behavior of the foams. The stress-strain relation is nonlinear, but typically there is a small range of linear behavior initially. Compressive cyclic loading at different amplitudes and frequencies of interest (20–60 Hz) were applied to measure foam’s hysteresis properties, i.e. stiffness and energy dissipation. The cyclic characterization includes foams with different amount of pre-strains, some are beyond the initial linear range as occurred in many applications.

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As an optimum energy-absorbing material system, polymeric foams are needed to dissipate the kinetic energy of an impact, while maintaining the impact force transferred to the protected object at a low level. Therefore, it is crucial to accurately characterize the load bearing and energy dissipation performance of foams at high strain rate loading conditions. There are certain challenges faced in the accurate measurement of the deformation response of foams due to their low mechanical impedance. In the present work, a non-parametric method is successfully implemented to enable the accurate assessment of the compressive constitutive response of rigid polymeric foams subjected to impact loading conditions. The method is based on stereovision high speed photography in conjunction with 3D digital image correlation, and allows for accurate evaluation of inertia stresses developed within the specimen during deformation time. Full-field distributions of stress, strain and strain rate are used to extract the local constitutive response of the material at any given location along the specimen axis. In addition, the effective energy absorbed by the material is calculated. Finally, results obtained from the proposed non-parametric analysis are compared with data obtained from conventional test procedures.

Dynamic stress-strain response of rigid closed-cell polymeric foams is investigated in this work by subjecting high toughness polyurethane foam specimens to direct impact with different projectile velocities and quantifying their deformation response with high speed stereo-photography together with 3D digital image correlation. The measured transient displacement field developed in the specimens during high stain rate loading is used to calculate the transient axial acceleration field throughout the specimen. A simple mathematical formulation based on conservation of mass is also proposed to determine the local change of density in the specimen during deformation. By obtaining the full-field acceleration and density distributions, the inertia stresses at each point in the specimen are determined through a non-parametric analysis and superimposed on the stress magnitudes measured at specimen ends to obtain the full-field stress distribution. The process outlined above overcomes a major challenge in high strain rate experiments with low impedance polymeric foam specimens, i.e. the delayed equilibrium conditions can be quantified.

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Experiments were performed to characterize the mechanical response of several different rigid polyurethane foams to large deformation. In these experiments, the effects of load path, loading rate, and temperature were investigated. Results from these experiments indicated that rigid polyurethane foams exhibit significant damage, volumetric and deviatoric plasticity when they are compressed. Rigid polyurethane foams were also found to be extremely strain-rate and temperature dependent. These foams are also rather brittle and crack when loaded to small strains in tension or to larger strains in compression. Thus, a phenomenological Unified Creep Plasticity Damage (UCPD) model was developed to describe the mechanical response of these foams to large deformation at a variety of temperatures and strain rates. This paper includes a description of recent experiments and experimental findings. Next, development of a UCPD model for rigid, polyurethane foams is described. Finite element simulations with the new UCPD model are compared with experimental results to show behavior that can be captured with this model.

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A Hopkinson bar was employed to conduct transverse impact testing of twisted Kevlar KM2 fiber yarns at the same impact speed. The speed of Euler transverse wave generated by the impact was measured utilizing a high speed digital camera. The study included fiber yarns twisted by different amounts. The Euler transverse wave speed was observed to increase with increasing amount of twist of the fiber yarn, within the range of this investigation. The higher transverse wave speeds in the more twisted fiber yarns indicate better ballistic performance in soft body armors for personal protection.

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The present work aims to investigate the bulk deformation and failure response of closed-cell Polymeric Methylene Diphenyl Diisocyanate (PMDI) foams subjected to dynamic impact loading. First, foam specimens of different initial densities are examined and characterized in quasi-static loading conditions, where the deformation behavior of the samples is quantified in terms of the compressive elastic modulus and effective plastic Poisson's ratio. Then, the deformation response of the foam specimens subjected to direct impact loading is examined by taking into account the effects of material compressibility and inertia stresses developed during deformation, using high speed imaging in conjunction with 3D digital image correlation. The stress-strain response and the energy absorption as a function of strain rate and initial density are presented and the bulk failure mechanisms are discussed. It is observed that the initial density of the foam and the applied strain rates have a substantial influence on the strength, bulk failure mechanism and the energy dissipation characteristics of the foam specimens.

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Numerous experiments were performed to characterize the mechanical response of several different rigid polyurethane foams (FR3712, PMDI10, PMDI20, and TufFoam35) to large deformation. In these experiments, the effects of load path, loading rate, and temperature were investigated. Results from these experiments indicated that rigid polyurethane foams exhibit significant volumetric and deviatoric plasticity when they are compressed. Rigid polyurethane foams were also found to be very strain-rate and temperature dependent. These foams are also rather brittle and crack when loaded to small strains in tension or to larger strains in compression. Thus, a new Unified Creep Plasticity Damage (UCPD) model was developed and implemented into SIERRA with the name Foam Damage to describe the mechanical response of these foams to large deformation at a variety of temperatures and strain rates. This report includes a description of recent experiments and experimental findings. Next, development of a UCPD model for rigid, polyurethane foams is described. Selection of material parameters for a variety of rigid polyurethane foams is then discussed and finite element simulations with the new UCPD model are compared with experimental results to show behavior that can be captured with this model.

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This report details a work in progress. We have attempted to calibrate and validate a Von Mises plasticity model with the Johnson-Cook failure criterion ( Johnson & Cook , 1985 ) against a set of experiments on various specimens of Al 6061-T651. As will be shown, the effort was not successful, despite considerable attention to detail. When the model was com- pared against axial-torsion experiments on tubes, it over predicted failure by 3 x in tension, and never predicted failure in torsion, even when the tube was twisted by 4 x further than the experiment. While this result is unfortunate, it is not surprising. Ductile failure is not well understood. In future work, we will explore whether more sophisticated material mod- els of plasticity and failure will improve the predictions. Selecting the appropriate advanced material model and interpreting the results of said model are not trivial exercises, so it is worthwhile to fully investigate the behavior of a simple plasticity model before moving on to an anisotropic yield surface or a similarly complicated model.

Foam materials are used to protect sensitive components from impact loading. In order to predict and simulate the foam performance under various loading conditions, a validated foam model is needed and the mechanical properties of foams need to be characterized. Uniaxial compression and tension tests were conducted for different densities of foams under various temperatures and loading rates. Crush stress, tensile strength, and elastic modulus were obtained. A newly developed confined compression experiment provided data for investigating the foam flow direction. A biaxial tension experiment was also developed to explore the damage surface of a rigid polyurethane foam.

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