Papers by Author: Bernard F. Rolfe

Abstract: Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to produce lighter weight, yet safer vehicles has led to the need to understand the crash behaviour of novel materials, such as fibre reinforced polymer composites, metallic foams and sandwich structures. This paper discusses the static indentation response of Carbon Fibre Reinforced Polymer (CFRP) tubes. The side impact on a CFRP tube involves various failure mechanisms. This paper highlights these mechanisms and compares the energy absorption of CFRP tubes with similar Aluminium tubes. The response of the CFRP tubes during bending was modelled using ABAQUS finite element software with a composite fabric material model. The material inputs were given based on standard tension and compression test results and the in-plane damage was defined based on cyclic shear tests. The failure modes and energy absorption observed during the tests were well represented by the finite element model.

Abstract: In this paper, an analytical model and its new numerical solution using the homogenization method are developed to determine the effective electromagnetic characteristics of honeycombs. Based on the proposed solution method, the electromagnetic properties are obtained by employing the multi-scale homogenization theory and periodical electric (magnetic) potential boundary conditions. Further, the effect of geometry of honeycomb’s unit cell on effective electromagnetic properties is investigated with the use of the proposed method. The numerical results are compared with analytic results using the Smith-Scarpa’s semi-empirical formula.

Abstract: In the car body stamping process, trim/blank die cutting edges are subjected to very high tribological loads that result in loss of tool material from both the punch and die cutting edges. According to Archard’s wear model, normal contact force and sliding distance directly affects the wear. Therefore, knowledge of the acting forces on local contact areas has a pivotal role towards the prediction of tool wear. This paper presents a finite element modelling approach to determining the contact pressure distribution on the tool cutting edges during a trimming/blanking process. Characteristic areas on sheared edge profile, variation of punch force and high contact pressures affected areas have also been analysed.

Abstract: Advanced High Strength Steels (AHSS) offer outstanding characteristics for efficient and economic use of steel. The unique features of AHSS are direct result of careful heat treatment that creates martensite in the steel microstructure. Martensite and carbon content in the microstructure greatly affects the mechanical properties of AHSS, underlining more importance on microstructural discontinuities and their multiphase characteristics. In this paper, we present the Multiscale Particle-In-Cell (MPIC) method for microstructural modelling of AHSS. A specific particle method [1] usually used in fluid mechanics is adapted and implemented in a parallel multiscale framework. This multiscale method is based on homogenisation theories; with Particle-In-Cell (PIC) method in both micro and macroscale, and offers several advantages in comparison to finite element (FE) based formulation. Application of this method to a benchmark uniaxial tension test is presented and compared with conventional FE solutions.

Abstract: For a given sheet metal forming process, an accurate determination of the contact pressure distribution experienced is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to determine the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by a transient response, which produced extremely large and localized contact pressures. Notably, it was found that the peak transient contact pressure was more than double the steady-state peak. These contact pressure results may have a significant influence on the tool wear response and therefore impact current wear testing and prediction techniques. Hence, an investigation into the validity of the predicted contact pressure was conducted.