On the random-based closed-cell metal foam modeling and its behavior in laser forming process

• Modeling of metallic foams are developed based on random distribution of random-sized spheres subtraction.
• Modeled foam is studied geometrically.
• Finite element simulation of laser forming process on metallic foam is carried out.
• Both geometrical and process validation of metallic foams is performed.
• Geometrical parameters effect in laser forming on foam sheets are investigated.

Metal foams are a new material category that, in the recent decade, are excessively used because of their good physical and mechanical properties such as low density and high stiffness. Regarding to their importance in engineering and other applications, modeling of metal foams are being studied and limited investigations have been carried out. The aim of this study is to develop a novel method to model the closed-cell metal foams. Closer modeling of foam sheets, which has an amorphous structure, are achieved by subtracting spheres with a random spatial position and random radius from an initial sheet rather than repeating a unit cell. In this article, the geometric properties of the closed-cell model is compared with the real foam. Also, finite element analysis of the laser forming process of the modeled foam is carried out. The effects of three geometrical parameters on bending angle is investigated. Both geometric comparison and FE validation shows a close agreement between numerical and actual results. Results show that relative density of the foam has the most effect and the mean cell size has the least effect on final bending angle.