Integration of mesoscopic lattice structures in crash-components

 

By establishing new manufacturing processes, in particular additive manufacturing, metallic lattice structures are becoming increasingly important in technical applications. With the help of such mesoscopic structures macroscopic structural properties can be generated. With conventional structures a change in the macroscopic behaviour is often limited, with regard of outer dimensions, whereas lattice structures offer nearby unlimited possibilities. By adapting mesostructural parameters, it is possible to influence the kinematics in a targeted manner, thus adjusting force and displacement redirections.

For crash applications mesostructural metal grids offer a great potential, in particular in the automotive engineering sector. With conventional designs the energy dissipation can be achieved only by extending the crash box or increasing the wall thickness. Above all a higher thickness is not reasonable, since this leads to higher reaction forces which can be critical for the occupants. Due to the fundamentally different energy absorption mechanisms of conventional crash components compared to those based on mesostructural grids, a completely new design potential is uncovered here.

As part of the project a new concept for the integration of mesostructural grids into crash components will be developed at the SLA to increase the specific energy absorption. For this purpose concepts for a realistic design of the component and efficient calculation methods must be identified. Analytical approaches for the mesostructure are combined with numerical tools for the macroscopic behaviour. The validation is done on real component tests.

 

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