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Structures composed of aviation aluminium alloys, characterized by their limited rigidity and thin-walled configurations, frequently exhibit deformation after processing. This paper presents an investigation into T-shaped components fabricated from pre-stretched 7075-T7451 aviation aluminium alloy sheets, examining the effects of residual stress and the geometrical parameters of T-shaped components on their deformational behavior. A semi-analytical model, developed to elucidate the bending deformation of T-shaped components subjected to residual stress, was validated through finite element analysis and empirical cutting experiments. The experimental results revealed that the bending deformation deflection of the T-shaped specimen was 0.920 mm, deviating by a mere 0.011 mm from the prediction provided by the semi-analytical model, resulting in an inconsequential error margin of 1.2%. This concordance underscores the precision and accuracy of the semi-analytical model specifically designed for T-shaped components. Moreover, the model's simplicity and ease of application make it an effective tool for predicting the bending deformation of thin-walled T-shaped components under a range of residual stresses and dimensional variations, thereby demonstrating its significant utility in engineering applications. [ABSTRACT FROM AUTHOR]

TPMS (triply periodic minimal surface) sheet structure consists of a spatially continuous surface, which forms a periodic porous structure, and has outstanding mechanical performance and ultralight weight. However, there are few studies on the periodic structure as an internal reinforcement energy absorber. In this study, we mainly discuss the collision ability of TPMS -filled square tubes under axial compression. Based on the numerical simulation results, it can be found that the unit-cell length and thickness of TPMS filler have great sway with the SEA and PCF of the TPMS-filled structure. The crashworthiness performance of TPMS-filled structures is better than the sum of separate structures attributed to the interaction effect. In addition, incomplete cell of the TPMS filler has a negative influence on the mechanical property at the low relative density and the shape of the TPMS filler can also affect the mechanical properties. To obtain an optimal TPMS-filled tube, a metamodel-based multi-objective optimization (MOO) method was employed to attain the Pareto front, in which the SEA is maximized and the PCF is minimized. It can be found that IWP-filled tube has maximum PCF among the four structures and FRD-filled tube owns maximum SEA. [ABSTRACT FROM AUTHOR]

Foam-filled thin-walled structure has been widely used in vehicle engineering due to its highly efficient energy absorption capacity and lightweight. Unlike the existing foam-filled thin-walled structures, a new foam-filled structure, i.e., functionally graded foam-filled graded-thickness tube (FGFGT), which had graded foam density along the transverse direction and graded wall thickness along the longitudinal direction, was first studied in this paper. Two FGFGTs with different gradient distributions subjected to lateral impact were investigated using nonlinear finite element code through LS-DYNA. According to the parametric sensitivity analysis, we found that the two design parameters n 1 and n 2 , which controlled the gradient distributions of the foam density and the tube wall thickness, significantly affected the crashworthiness of the two FGFGTs. In order to seek for the optimal design parameters, two FGFGTs were both optimized using a meta-model-based multi-objective optimization method which employed the Kriging modeling technique as well as the nondominated sorting genetic algorithm II. In the optimization process, we aimed to improve the specific energy absorption and to reduce the peak crushing force simultaneously. The optimization results showed that the FGFGT had even better crashworthiness than the traditional uniform foam-filled tube with the same weight. Moreover, the graded wall thickness and graded foam density can make the design of the FGFGT flexible. Due to these advantages, the FGFGT was an excellent energy absorber and had potential use as the side impact absorber in vehicle body. [ABSTRACT FROM AUTHOR]