Finite element modelling of the mechanism of deformation and failure in metallic thin-walled hollow spheres under dynamic compression

Recent interest in lightweight metallic hollow sphere foams for aerospace applications requires a better physical understanding of dynamic properties of single spheres. Finite element modelling supported by high rate experiments was developed to investigate the underlying deformation and failure mechanisms of electrodeposited nickel thin-walled hollow spheres. Parametric simulation was performed to further explore the effect of sphere geometry (wall thickness to diameter ratio) and loading rate. It was found that decreasing the ratio of wall thickness to diameter tends to transit the side wall failure mode from bending to buckling. For a thin-walled sphere (the thickness to diameter ratio less than a critical value), the macroscopic dynamic behaviour is primarily dominated by the two deformation and failure mechanisms: (1) buckling failures of wall materials and (2) self-contacts of wall surfaces and wall-anvil contacts. At higher impact velocity (greater than a critical velocity), inertia effect due to dynamic localisation of wall crushing arises and significantly influences the deformation/failure mode of the sphere, resulting in an increased initial crushing strength and asymmetric deformation. Finally, the behaviour of hollow spheres was correlated to explore the power law behaviour of bulk foams with respect to the relative density; it was found that metallic thin-walled hollow sphere foams can be better approximated as open-cell rather than closed-cell foams.

► A FE model explores dynamic deformation and failure in thin-walled hollow spheres.
► Parametric simulation investigates the effect of wall thickness to diameter ratio and loading rate.
► Buckling failure and interfacial contacts of sphere wall are dominant mechanisms.
► Dynamic localisation of crushing is main mechanism at higher impact velocity.
► Bulk thin-walled hollow sphere foams can be better approximated as open-cell foams.