Parameterized optimal design of a novel cellular energy absorber

• Numerical modeling of a novel polymeric cellular energy absorber—SKYDEX® material.
• Development of a new twin-hemishperical microstructure based on the SKYDEX® cell.
• Computational studies on the deformation modes, strength and energy absorption of the newly developed microstructure.
• Optimal design of the newly developed microstructure.
• Parametric studies on the multilayered microstructures.

As an advanced lightweight porous medium, SKYDEX®material has been applied as the energy absorbing structures for personnel protection. Its hourglass-like microstructures made of thermoplastic can dissipate kinetic energy and reduce pressure transfer during crushing. Based on the SKYDEX® cell, this paper develops a novel twin-spherical microstructure, where the shape and size were represented with two key geometric parameters. 3D finite element models were then constructed to demonstrate the cellular deformation modes with different configurations along with the quantitative responses in terms of the energy absorption and pressure transfer. An optimization was performed to find the best design. Using this optimal configuration thus obtained, models with multilayers were built, and each layer was either uniformed or graded in density. Their responses under low and high speed compressive loadings were compared, and the results showed that the direction and degree of the density gradient as well as impact velocity are important parameters affecting the energy absorbing capability.

This paper develops a novel twin-spherical microstructure, where the shape and size were represented with two key geometric parameters (left). 3D finite element models were then constructed to demonstrate via simulation the cellular deformation modes (right) with different configurations along with the quantitative responses in terms of the energy absorption and pressure transfer. An optimization was then performed to find the best design at single or multiple layers.Figure optionsDownload as PowerPoint slide