Modelling, Simulation and Optimization of Crash Components in Aluminium
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The main focus of this thesis was to establish a validated finite element model of an extruded rectangular hollow profile with a single chamber. Experimental axial crushing tests were carried out on various heat treated 6xxx-series aluminium alloys and used to validate the established finite element model. Additional emphasis was put on the comparisons between the material data obtained from the nanostructure model, NaMo, and the calibrated material model from the conducted tensile tests. The basis model was established in Abaqus/Explicit prior to conducting any experimental work, and served as validation to what extent we are able to predict the crushing behaviour of a generic crash box. The results from the basis model were very accurate overall, and hence the parametric study provided few changes to model. The calibrated material data increased the accuracy of the model even further, and the results may be regarded as excellent. With the exception of a few outliers, the material data from NaMo and the calibrated material model coincided well.Deviations between the numerical and experimental results were observed in the O-tempers for the material data from NaMo as well as the calibrated material model. In general, the numerical models seemed to capture the response of the axially loaded crash boxes in a satisfactory manner. The predicted results were surprisingly accurate in comparison to the experimental results, and served as validation of the accuracy of the material data calculated by NaMo.