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This paper proposes an innovative class of two-and-a-half dimensional (2.5D) hybrid continuous fiber reinforced lattice structures (CFRLSs) that rationally combine distinct lattice designs to leverage the tensile strength of fibers for achieving superior compression performance. These hybrid structures are fabricated through a self-supporting suspension printing (SSSP) method, which enables the fabrication of suspension structures across substantial gaps through continuous fiber 3D printing (CF-3DP). The compression behavior of the proposed 2.5 D hybrid CFRLSs was optimized by focusing on two key variables in hybridizing the basic lattice along the build direction: composition ratio and distribution strategy. Finite element and analytical models were developed to elucidate their three failure mechanisms and related control strategies. Compared to the conventional single-type structure, i.e., honeycomb design, the proposed hybrid structures show a substantially higher compression performance, with improvements of up to 141.3 % and 330.1 % in specific strength and modulus, respectively, even at a lower density. This hybrid lattice design method based on SSSP opens up new horizons for engineering high-performance CFRLSs with superior compression performance by fully exploiting the design freedom offered by CF-3DP. [Display omitted] [ABSTRACT FROM AUTHOR]

• A new type of T-beam bridges deck: honeycomb T-beam. • Static comparison test of conventional T-beam and honeycomb T-beam. • Finite element model verified by static test. • Calculation of crack width and reinforcement optimization. The inefficiency in the construction of intermediate diaphragms for T-beam bridges (referred to as conventional T-beam), has long been a significant research concern. This study focuses on a novel bridge deck design (referred to as honeycomb T-beam), which effectively eliminates the need for intermediate diaphragms, thus enhancing construction efficiency. Segment models of both conventional T-beam and honeycomb T-beam were designed and fabricated, and their transverse mechanical performance was compared through transverse static tests. Additionally, numerical simulations using ABAQUS were conducted and validated with experimental data. Based on the numerical model of honeycomb T-beam, crack width calculation and reinforcement optimization were performed. The main conclusions are as follows: (1) The design of honeycomb T-beam allows for less reinforcement, making it more economical while ensuring that the bearing capacity reaches the same level. (2) Honeycomb T-beam exhibits superior durability and bearing capacity, with a failure mode that is more ductile. (3) The results of numerical simulation highly coincide with experimental results. Besides, this paper proposes and validates a practical method for crack width calculation. (4) Parametric analysis show that increasing the reinforcement area at right inner hole of honeycomb T-beam by 10% can enhance the bearing capacity by 18%. Based on this, design suggestions are made for honeycomb T-beams and other perforated structures. [ABSTRACT FROM AUTHOR]

Thermal characterization of honeycomb core sandwich panels with GFRP skins by theoretical formulations, and experimental methods followed by corroborating numerical models help identify the effective thermal conductivity in both the out-of-plane and in-plane directions. Swann–Pitman's semi-empirical model formed the basis for the theoretical understanding of heat transfer in honeycomb core sandwich panels. Experimental approach involved a setup based on guarded hot plate (GHP) apparatus, and transient laser flash technique while the numerical approach involved FE modeling of the woven composite fabric face sheet by multi-scale modeling using the actual physical dimensions of the yarn e.g., crimp angle, width and height of the yarns etc. obtained using microscopic analysis. The fiber volume fraction of the experimental samples was estimated both by image analysis and burn-off method using Thermogravimetry (TGA). Various numerical models based on Mechanics of Structure Genome (MSG) and randomized fiber distribution in the yarns at the micro-level are compared with the experimental results to arrive at the model that most closely mimics real situation. Then, the numerical model is used to predict the thermal conductivity of the composite as the fiber volume fraction and crimp angle varies. • Heat flow in sandwich structures with composite facesheets is dominated by core cell wall conduction. • Better representative RVE model of the composite yarns using data from micrograph images, and Procrustes analysis. • E-glass/polypropylene facesheets perform better at low crimp angle and fiber volume fraction (V f). • Small "resin-rich" matrix region disrupts heat flow in facesheets. [ABSTRACT FROM AUTHOR]

• Three new multi-directional energy-absorbing honeycombs are further designed. • The multi-directional energy absorption characteristics are experimental analyzed. • Detailed and equivalent FE model of corrugated honeycomb are developed and validated. • A new anti-climber equipped with corrugated honeycomb that saves half of the installation length is designed. • The new anti-climber exhibits high energy absorption and strength performance, respectively, in axial and vertical directions. In this study, three novel multi-directional energy-absorbing honeycombs were designed to meet the requirements in the crash of uncertain directions, which are named as bow-shaped honeycomb (BSHC), staggered honeycomb (SGHC) and corrugated honeycomb (CGHC). These innovative designs can significantly narrow the huge gap of the energy absorption capacity between the in-plane and out-of-plane directions of traditional honeycombs. Compression tests were conducted in three orthogonal directions. The BSHC is found to have the smallest densification strain but the highest plateau stress in each direction. The SGHC can only balance the energy absorption between out-of-plane and in-plane- x directions. The CGHC demonstrates a better densification strain and the highest multi-directional energy absorption coefficient. The detailed and equivalent finite element models of CGHC were further established and validated, and both exhibited high accuracy. Finally, a honeycomb anti-climber, with only about half length of the traditional guided honeycomb anti-climber, was designed and equipped with metro vehicles. Simulations were conducted under eccentric collision scenario. The results demonstrated that the CGHC anti-climber was capable of orderly deformation in the axial direction (out-of-plane direction) while effectively resisting the vertical (in-plane- y direction) force during collision. The energy absorption capacity of CGHC anti-climber was significantly enhanced as compared to the HEHC anti-climber under eccentric collision scenario. [ABSTRACT FROM AUTHOR]

Real-time thermal deformation monitoring plays a crucial role in calibrating phase signals and maintaining satellite performance for large spaceborne antennas. The inverse finite element method (iFEM) represents a promising shape-sensing methodology applicable to monitor the three-dimensional displacement of structures through surface-measured strain. However, the high-accuracy reconstruction of large-scale structures involves a large number of inverse elements, which leads to the low level of computational efficiency. To address this issue, a displacement-gradient-based variable-size iFEM is proposed in this paper. According to the characteristics of deformation, this method optimizes the size of each inverse element to reduce the number of inverse elements required, which improves real-time performance and maintains the high accuracy of reconstruction. The real-time performance of the proposed method is verified by conducting a simulation test on a large-scale honeycomb antenna. According to the simulation results, the variable-size iFEM is applicable to achieve the same accuracy of reconstruction using fewer inverse elements than conventional iFEM. An experimental test is performed and the optimal variable-size discretization that balances accuracy and efficiency is determined. The results show that the maximum error of reconstructed displacement is less than 7.3 % and the reconstruction time is in no excess of 0.1 s. [ABSTRACT FROM AUTHOR]

• Hybrid ultrasonic vibration assisted machining significantly improves Nomex machining quality by reducing cutting forces. • Depth of cut has a significant effect on Nomex honeycomb composite (NHC) cutting forces. • Ultrasonic toothed disc cutter (UTDC) significantly reduces tearing of NHC cell walls, delamination and uncut fibers. • UTDC produces higher number of burrs with shorter length compared to plane disc cutter. • Better machining quality and efficiency of NHC core can be achieved by suitable combination of the machining parameters. Nomex honeycomb composite (NHC) has been increasingly used in the automotive, aerospace and defence applications due to its excellent thermal and mechanical properties. Its complex cellular hexagonal thin-walled configuration along with heterogeneous, soft and brittle nature pose substantial processing defects such as burr formation, tearing of walls, surface roughness, dimensional inaccuracy and low machining quality during conventional machining (CM). These surface defects have a substantial influence on the operating life and functional performance of its sandwiched structural members. Hybrid ultrasonic vibration assisted machining (HUSVAM) technology has been introduced to overcome such limitations. For an in depth research on HUSVAM of NHC using ultrasonic toothed disc cutter (UTDC), three dimensional finite element model was developed and experimental validation was carried out. The numerical simulation and experimental results were found to be in good agreement with one another. The influence of various machining parameters including the ultrasonic tool vibration amplitude (UTVA), feed rate (FR), depth of cut (DoC) and spindle angular speed (SAS) on NHC cutting forces, chip formation and surface quality was investigated using both HUSVAM and CM techniques. Furthermore, stresses, deformation and forces near tool-workpiece interaction along with the surface topography and morphologies were also analysed and compared for various operating conditions. A reduction in the cutting forces was found with the increase of SAS and UTVA (up to 65.47 % and 65.74 %, respectively). Although, the cutting forces were observed to increase by increasing the DoC and FR (up to 159.45 % and 126.33 %, respectively). DoC has a greater impact on the cutting forces among all machining parameters according to 4 levels, 4 factors (L 16) orthogonal experiments based on Taguchi method. The results show that the chip formation and machining quality of NHC core can be improved with HUSVAM technique using UTDC. HUSVAM also reduced the cutting forces (up to 73 %) compared to CM. The ultrasonic toothed disc cutter generated large number of burr with very short length, no tearing defects and no uncut fibers as observed from scanning electron microscopy of NHC hexagonal cell structure, walls and triple points. A burr formation of less than 10 % was realized during HUSVAM of NHC cores for F x ≤ 3 N , while it was found up to 20 % if F x > 3 N , compared to at least 40 % during CM. The finite element model developed can be used to investigate the influence of HUSVAM on modern difficult to machine materials for enhanced surface quality. [ABSTRACT FROM AUTHOR]

In this study, an inverse design framework was constructed to explore gradient honeycomb structures (HCS) with high impact resistance. By establishing the relationship between the height of the cell and the cell-wall angle, HCS with different gradient modes were designed. The developed machine learning (ML) framework consisted of a forward regression model based on neural network (NN) and an inverse optimization model based on generative adversarial network (GAN). The regression model surrogated finite element analysis (FEA) to rapidly provide corresponding mechanical properties for the generated data of GAN. To ensure that the generated data met the desired design targets, additional physical constraints were incorporated into the generator of the GAN. This ensured that the network output not only consisted of valid data but also exhibited superior impact resistance. The results demonstrated that the trained ML model optimized both specific energy absorption (SEA) and initial peak stress of HCS. It even discovered high-performance gradient designs that outperformed the original data, with a maximum energy absorption 49.5% higher than that of uniform HCS. Moreover, the gradient modes and structural parameters of superior designs were identified, which is of great significance for the gradient design of HCS under impact loading. As a general design approach, this ML framework holds significant potential for the optimization design of metamaterials in other structures or with different mechanical properties. • A inverse design framework for finding high impact resistance HCS is proposed. • Using NN surrogate FEA to accelerate the prediction of structural performance. • The design of desired properties can be obtained by introducing physical constraints. • The multi-layer HCS with different gradient modes is evaluated. [ABSTRACT FROM AUTHOR]

• The proposed auxetic honeycomb possesses more excellent auxetic behavior and specific energy absorption than the conventional honeycomb. • The interaction between the structural parameters is analyzed. • The multi-objective optimization of the enhanced auxetic honeycomb (EAH) was investigated. • The theoretical model and Box-Behnken Design model were used to predict the mechanical properties of EAH. In response to the challenge of low stiffness and energy absorption capacity, various designs of negative Poisson's ratio (NPR) structures have emerged. However, these designs often lack a comprehensive analysis of other mechanical properties, leading to subpar mechanical performance. Previous studies have explored the mechanical properties response of enhanced re-entrant honeycombs (ERH) under impact conditions, revealing limitations in optimizing the structure's performance with a single objective. Therefore, this study aims to enhance ERH structural parameters to achieve superior mechanical performance through theoretical derivations and geometric optimizations. The results demonstrate that the proposed theoretical model is consistent with finite element analysis and response surface (RS) predictions. Expressions for Young's modulus, specific energy absorption, and compressive strength are proposed, facilitating the identification of structural parameters that meet specific requirements during reverse design. Furthermore, a multi-objective optimization approach optimizes the geometric parameters based on maximum energy absorption and compressive strength. The mechanical behavior of the optimized ERH is investigated using the finite element method, revealing the energy absorption capacity of 13.78 J/g while maintaining Poisson's ratio at -1.06. Additionally, the deformation mode of the optimized structure showcases enhanced stability compared to traditional honeycomb structures. The theoretical model and RS method were used to guide the design of ERH and promote the application of NPR structures. [ABSTRACT FROM AUTHOR]

Aluminum honeycomb core (AHC) is extensively applied in aerospace and transportation industries for its exceptional strength-to-weight ratio. However, the unique structure of AHCs limits their manufacture. In this research, the damage mechanism of AHCs is firstly studied with polycrystalline diamond (PCD) circular saw blades to provide high-quality AHCs for wide-format honeycomb composites. The study meticulously examines the various forms of sawing damage incurred by AHCs at different material removal rates (MRR) and categorizes them accordingly. The results show that burrs of AHCs change from tiny blocks to larger strips with the MRR. At high MRR, the predominant failure modes include collapse, deformation, and hot cracking, while at low MRR, AHCs mainly suffer from cracking, micro-collapse, and oxidation by SEM and EDS analysis. A dynamic analytical model of the sawing angle is proposed based on the sawing trajectory to elucidate vibration scratching and burr formation. The effect of the sawing angle is quantified by the deformation displacement and damage area by the optical measurement. The microscopic reciprocating vibration scratching of AHCs is interpreted by the blade's vibration state. The causes of sawing damage at different MRRs are investigated, indicating that at high MRR, the increased impact of the sawtooth leads to severe vibration scratches, collapses, and strip burrs, whereas, at low MRR, the high-frequency scratching of the sawtooth tends to result in tearing and micro-collapses. A comprehensive description of burr formation is presented by a 3D finite element model. Additionally, the cutting heat is the main cause of the oxidation of sawing surfaces by EDS. This systematic investigation analyzes and explores the sawing damage mechanisms of AHCs, offering in-depth insights for optimizing the sawing process to eliminate surface quality problems and improve the sawing efficiency and accuracy of wide-format AHCs. [Display omitted] • Aluminum honeycomb materials can be manufactured by high-speed sawing for obtaining wide-format honeycomb cores. • The damage mechanisms of aluminum honeycomb cores under different material removal rates were finely analyzed and classified. • A dynamic analytical model of sawing angle based on sawing trajectory is proposed. • The sawing burr formation was fully described by 3D finite element modeling. [ABSTRACT FROM AUTHOR]

• Innovative metamaterial design approach proposed to improve energy absorption capacity. • Varying the structural parameter (D/d) enhanced the metamaterial auxetic effect. • HPH metamaterials absorb energy effectively horizontally with their honeycomb structure. • HPH metamaterials show excellent reusability at lower compression ratios. Hexagonal perforated honeycomb (HPH) metamaterials were designed, fabricated and investigated in this work. Initially, the mechanical properties and deformation modes of various proposed HPH metamaterials (HPH-U, HPH-1 L and HPH-3 L) under quasi-static vertical compression were analyzed using experimental and finite element methods. The findings reveal significant improvements in mechanical properties and energy absorption due to the honeycomb and hierarchical expandable design. Notably, the auxetic effect is diminished. Subsequently, the impact of key dimensional parameters on the mechanical properties and Poisson's ratio behavior was explored. The results highlighted that an increase of elliptical perforation major axis to minor axis ratio enhanced the auxetic effect but compromised load-bearing and absorptive capacity. Additionally, HPH metamaterials displayed exceptional performance under quasi-static horizontal compression, with their honeycomb structure enabling them to withstand both vertical and horizontal impacts while exhibiting excellent energy absorption capabilities. The study also identified relative density as a crucial factor influencing horizontal impact performance. Finally, the study subjected the HPH metamaterials to multiple quasi-static vertical repetitive compressions, meticulously analyzing variations in mechanical properties under diverse compression ratios. Due to distinctive structural design and impressive mechanical properties, HPH metamaterials demonstrate immense potential for applications in automotive engineering and sports protection fields. [Display omitted] [ABSTRACT FROM AUTHOR]

• 2.5D woven carbon-fiber honeycomb sandwich structures was manufactured and investigated both experimentally and numerically. • Effects of varied parameters of the sandwich structure on the mechanical, especially the energy absorption characteristic were investigated through quasi-static indentation experiments. • The panel strength and honeycomb core strength were found synergistically determine the failure mode of the sandwich structure. Here, a new type of sandwich structure made of fiber metal laminates (FMLs) as facesheet and 2.5D woven carbon-fiber (CFRP) honeycomb as core was developed. The FMLs/CFRP honeycomb sandwich structures were subjected to quasi-static indentation tests to investigate the mechanical response with the variation of panel structure, honeycomb cell element size, honeycomb core wall thickness, and honeycomb core height. In addition to experiments, a finite element method (FEM) model was also created in ABAQUS/Explicit to analyze the damage mechanisms and failure modes of honeycomb sandwich structures under quasi-static indentation. Both the experimental and FEM simulation results revealed that the honeycomb sandwich structure underwent two different failure modes under quasi-static loading: localized damage dominated by indentation and global damage due to overall bending deformation. The combination of panel strength and honeycomb core strength determined the failure mode of the sandwich structure. Damage analysis of the honeycomb core showed that it mainly underwent fiber compression damage and matrix compression damage under quasi-static indentation. This study provides guidance to optimize the design of honeycomb sandwich structures. [ABSTRACT FROM AUTHOR]

A star-shaped honeycomb with asymmetric cells is proposed in this paper. The accuracy of the finite element model is verified by experiments, and the mechanical characteristics and deformation modes of the honeycomb are studied by numerical simulation. First, the energy absorption and deformation modes of a star-shaped honeycomb with asymmetric cells were studied under low-, medium- and high-velocity impacts. Second, the influence of different angles and different wall thicknesses on the energy absorption of honeycomb was studied. The results show that model 3 exhibits obvious negative Poisson's ratio characteristics under different impact velocities. As the angle increases, the energy absorption and plateau stress of mode 1 also increase. However, for mode 3, increasing θ can enhance the negative Poisson's ratio, but the specific energy absorption and plateau stress of the structure will decrease. Compared with the traditional star-shaped honeycomb, θ = 50° for mode 1, the specific energy absorption and plateau stress are increased by 21.53% and 13.32%, respectively. With increasing wall thickness, the specific energy absorption and plateau stress were significantly increased. Compared with mode 1 with t = 0.5 mm and mode 1 with t = 0.75 mm, the specific energy absorption and plateau stress increased by 50.51% and 125.56%, respectively. • A star-shaped honeycomb with asymmetric cells (SSHAC) is proposed. • The SSHAC is designed in an axisymmetric manner, with six structures designed in different extension directions. • Compared with traditional star-shaped honeycomb, SSHAC has a more stable deformation mode. • SSHAC provides a certain reference for cells designed with asymmetric elements in symmetrical form. [ABSTRACT FROM AUTHOR]

[Display omitted] • The innovative metamaterials with high load-bearing capacity and low-frequency multi-bandgaps are proposed and optimized based on assembly concept. • The incorporation of metal pins enhances the local stiffness, thereby improving the load-bearing ability of the metamaterial. • The metal pins play a crucial role in generating low-frequency multi-bandgaps by adjusting the local resonant modes. • The structure of particle damping can conveniently adjust the frequency of the resonant bandgaps and further dissipate the vibration energy. This study presents a novel star-shaped honeycomb meta-material (N-SSHM) that realizes improved static mechanical and vibration properties by introducing rings to the four sides of a traditional star-shaped honeycomb meta-material (T-SSHM). Optimization of the static and vibration suppression properties is achieved using the assembly concept. The static properties of the proposed meta-materials are initially investigated using the finite element method (FEM) and static compression tests. The results demonstrate that the N-SSHM exhibits a superior load-bearing capacity compared to the T-SSHM. Subsequently, the vibration properties of the meta-material are studied using simulations and experiments. The wave propagation characteristics of the meta-materials are explored by introducing the phase velocity and group velocity. The study also examines the effects of design parameters (ring size, metal pin size, and pin material) on the bandgap characteristics, and the vibration suppression properties of the meta-material are further enhanced by introducing particle damping. The simulation and experimental results confirm that the proposed N-SSHM has a lower starting frequency and wider bandwidth for the bandgap than the T-SSHM. In summary, the N-SSHM demonstrates significant improvements in both load-bearing and vibration suppression compared to the T-SSHM. This study provides support for the engineering applications of meta-materials. [ABSTRACT FROM AUTHOR]

• An attractive structure with superior dynamic crushing performance was proposed. • Reliable numerical models were established to avoid severe element distortion. • Dynamic crushing response was illuminated in the full range of deformation process. • The effects of strain-rate sensitivity and impact velocity were evaluated in depth. To achieve excellent dynamic crushing performance, an attractive foam-filled periodic hybrid cellular (F-PHC) structure containing both hexagonal and re-entrant cells was designed and fabricated. Dynamic crushing experiments for foam-filled PHC structures were carried out using a direct impact Kolsky bar testing system. Reliable numerical simulations using both finite element method and smoothed particle hydrodynamics method were developed to analyze the dynamic crushing responses of F-PHC structures in the full range of deformation processes. Effects of inertia, strain-rate sensitivity, cell number, and impact velocity were evaluated. The results show that the dynamic plateau stresses of periodic hybrid cellular structures can be substantially enhanced by filling foams. The dynamic crushing response of F-PHC structure is very susceptible to impact velocity due to inertia effect. Compared with foam-filled hexagonal honeycomb and foam-filled re-entrant honeycomb structures, F-PHC structures exhibited superior dynamic crushing performances, including smoother and longer dynamic plateau stresses, more uniform deformation distributions, and much more stable deformation processes. Moreover, F-PHC structures exhibited much lower dynamic initial peak stresses at the rear face. This study provides a fascinating design idea and shines light on attractive F-PHC structures with a promising application prospect in the field of impact protection. [ABSTRACT FROM AUTHOR]

• Inspired by self-similar evolution, a novel concave-convex hierarchical honeycomb (NCHH) is proposed. • The NCHH show the characteristics of concave and convex, and the energy absorption characteristics of concave honeycomb is better than that of convex honeycomb. • Reasonable configuration of self-similarity coefficient, angle and wall thickness can effectively improve the crashworthiness of the structure under axial impact. A novel bi-directional hierarchical honeycomb is proposed. A finite element numerical model was constructed using Abaqus/Explicit, the model's accuracy was verified, and a series of in-plane impact studies were carried out. Firstly, the mechanical properties of axial impact were analyzed for different bi-directional hierarchical honeycombs. The results show that the mechanical properties of NBHH- h 1 h 2 2 h 3 -III and NBHH- h 1 h 2 h 3 h 4 -IV are the best and almost identical. Subsequently, the mechanical properties of NBHH-X h x Y h y -IIs with different layers were analyzed. Research results show that NBHH- h 3 3 h 4 -II has a 77.96 % increase in specific energy absorption (SEA) compared to NBHH- h 1 3 h 2 -II, and NBHH- h 1 3 h 2 -II has a 116.02 % increase in SEA compared to NBHH-3 h 1 h 2 -II. A parametric study of NBHHs was conducted. The mechanical properties of NBHHs with different layer ratio coefficients were analyzed, and it was found that the mechanical properties of NBHHs with l 2 = 12 and k = 0.2 are the best. Finally, the effects of wall thickness and velocity on NBHHs were analyzed. Increasing the wall thickness appropriately can effectively improve the impact resistance of the structure. Bi-directional hierarchical design provides a practical reference for enhancing the in-plane mechanical properties of honeycombs. [ABSTRACT FROM AUTHOR]

The core layer of accordion honeycomb sandwich panel (accordion HSP) exhibits exceptional affinity for one-dimensional curvature deformations due to its special zero Poisson's ratio effect. This study thoroughly examines its static and dynamic characteristics by decomposing the analysis into unit-cell constitutive modeling and a two-dimensional equivalent-oriented model (2D-EOM) through the variational asymptotic method. The unit-cell constitutive modeling enables determining equivalent stiffness properties for the 2D-EOM. To validate the accuracy and efficiency of the proposed 2D-EOM, its results are compared against those obtained from a detailed 3D finite element model, including in-plane and out-of-plane behaviors of the core layer and sandwich panel, as well as free and random vibration under diverse excitation conditions. The comparison results demonstrate a significant three-fold increase in the equivalent stiffness of the accordion honeycomb in the direction of the added ligaments, as compared to the re-entrant honeycomb. Simultaneously, the acceleration amplitude of the accordion HSP is effectively reduced by 4% due to the involvement of lower high-order frequencies, rendering it exceptionally suited for shockproof meta-structural applications. This equivalent model not only fulfills accuracy requirements but also improves computational efficiency by 15 times, providing an effective approach for preliminary design of honeycomb sandwich panels. • Exceptional affinity for 1D curvature deformations due to ZRP effect of accordion core. • Comprehensive analysis of static and random dynamic characteristics of accordion HSPs. • Enhanced computational efficiency of 2D-EOM while maintaining sufficient accuracy. • Increased stiffness achieved by incorporating ligaments into accordion honeycombs. • Reduced acceleration amplitude due to involvement of lower higher-order frequencies. [Display omitted] [ABSTRACT FROM AUTHOR]

The battery-pack system of electric vehicles is prone to collide with low obstacles on the road, causing battery short circuits and even explosions. It poses a great safety threat to passengers and drivers. The honeycomb structure's high energy absorption and lightweight properties have made it a popular choice in the automotive industry. This paper designs different bio-inspired honeycomb structures to a battery-pack system of electric vehicles to improve the crashworthiness performance. The effects of different bio-inspired honeycomb structures on the crashworthiness of a battery-pack system during frontal impact are analyzed based on a nonlinear finite element model. First, the geometric parameters of seven different bio-inspired honeycomb individual units are described. The overall structure of the honeycomb is applied to a battery-pack system. Second, the nonlinear finite element model of a battery-pack system and honeycomb structures are established and verified. Then, collision simulations are conducted. The deformation and the maximum stress of a battery-pack's bottom shell are computed. The energy absorbed by the honeycomb structures during frontal impact are investigated. The results indicate that the proposed bio-inspired honeycomb structure mimicking grass stems improves the safety performance of battery-pack systems most. Finally, a parametric design is carried out on the bio-inspired honeycomb structure. The effects of wall thicknesses and the number of replacement hexagons on the crashworthiness performance are analyzed. The honeycomb structure preforms best when thickness is 1 mm and the number of replacement hexagons is 2 and 4. The optimized bio-inspired honeycomb structure reduces the deformation of the battery-pack' bottom shell by up to 30%, and maximum stress by 10%. • The deformation, maximum stress, and energy absorption are investigated. • The effects of seven bio-inspired honeycomb structures are analyzed. • Parametric design is carried out to further improve the crashworthiness performance. • The deformation of the bottom shell can be reduced by up to 30%. [ABSTRACT FROM AUTHOR]

• The connection performance of honeycomb plate-rod composite structure based on different connection methods were compared. • The applicable finite element analysis methods of three connection methods were obtained. • The influence of the connection spacing, connector diameter and plate thickness on the composite structure was discussed. • The shear and bending bearing capacity formula of composite structure were proposed by theoretical derivation and BP algorithm. The connection design method of plate-rod composite structure is very important for the cooperative work of plate and rod. In this study, ten kinds of plate-rod composite structures of different connection methods, connection spacings, and plate thicknesses were designed to examine the connection performance of composite structure. The applicable finite element analysis methods of three connection methods were obtained by comparing the calculation results of finite element simplification models. The influence of connection spacing, connector diameter and plate thickness on the connection performance of three connection methods was studied by parametric analysis. The optimized shear bearing capacity formula of three connection methods were proposed based on the connection performance test and the design specifications at home and abroad. The bending bearing capacity formula of composite structure were proposed by theoretical derivation and finite element analysis, and the relevant parameters were fitted by the Backward Propagation (BP) algorithm in neural network. The results shown that the connection performance of Self-Piercing Riveting connection is obviously better than that of one-side bolt and core-pulling rivet connection, and the bearing capacity is increased by about 6 % and 10 %. The connector solid (So-1-1), solid simplified beam (So-3-1 and So-3-2), and shell simplified beam (Q-1) modeling method can better simulate the one-side bolt connection, and the error is within 3 %. The connector solid (So-1-2), solid beam (So-2-1), embedded (So-4-1), and shell simplified beam (Q-1) are suitable for core-pulling rivet connection, and the error is within 5 %. All the finite element analysis simplification methods can accurately simulate the Self-Piercing Riveting connection except for the Q-2, and the error is within 2 %. The bearing capacity of the composite structure increases with the increase of the connector diameter, the decrease of the connection spacing and the increase of the plate thickness. The optimized shear bearing capacity formula are more suitable for practical application, and the error of the bending bearing capacity formula of composite structure is within 5 %, which provides a certain reference for the design of honeycomb plate-rod composite structure and the revision of relevant specifications in the future. [ABSTRACT FROM AUTHOR]

• Effects of heating and cooling thermal shock on thermally induced vibration (TIV) are explored. • Influence of geometric nonlinearity under heating/cooling thermal shock forms is revealed. • The TIV characteristics of sandwich beams with auxetic honeycomb cores are discussed and compared with traditional honeycomb. • The instability conditions of the clamped beam with immovable ends under heating thermal shock are given. The nonlinear thermally induced vibration (TIV) characteristics of sandwich beams with auxetic honeycomb cores under general boundary conditions are studied. Based on first-order shear deformation theory, the dynamic governing equations are obtained through Hamilton principle, in which geometric nonlinearity and temperature dependence are considered. The temperature field along the thickness is calculated by finite element method and nonlinear TIV responses are solved via Newton-Raphson-Newmark method. The effects of temperature dependency, thermal shock forms, geometric nonlinearity, thicknesses of beam and face-sheet, boundaries and honeycomb geometrical parameters are studied. Results show that the reduction of the absolute inclined angle of the auxetic honeycomb can weaken the TIV responses. The influence of geometric nonlinearity on quasi-static and dynamic responses depends on the thermal shock form. Thermal buckling is the necessary condition for the occurrence of the TIV in clamped beams with immovable ends. Moreover, the research provides some design references to suppress the TIV responses of the sandwich beam with auxetic honeycomb core. [ABSTRACT FROM AUTHOR]

• A novel composite auxetic reentrant honeycomb structure is designed and fabricated. • The underwater impact properties of composite reentrant honeycomb structure were explored and analyzed by experiment and finite element analysis. • The effect of gradient form, peak pressure and decaying time on the fluid-structure interaction was analyzed and revealed. • The effect of cavitation of composite reentrant honeycomb structure was analyzed and investigated. In this paper, the effects of the gradient form, peak pressure and decaying time on the fluid-structure interaction of composite auxetic re-entrant honeycomb structures was experimentally and numerically investigated. The specimens for this experiment were manufactured by hot-press molding method. The acrylic transparent tube was utilized to accommodate water medium, pistons and specimen during experiment. The exponential decaying shock wave was simulated by accelerating the fly plate to impact the piston based on the one-stage light gas gun system. The incident velocity of the fly plate and process of the fluid-structure interaction response were monitored by high frame rate camera. In addition, the velocity of the shock wave in water was measured by transducers installed at different measuring points. The voltage signal of the dynamic overpressure collected by transducers was amplified by the charge amplifier and recorded by the oscilloscope. On the other hand, finite element software Abaqus/Explicit was applied to simulate the cavitation process of water domain and dynamic response of specimens. The experimental results and numerical results were in good agreement. The results indicated that the increase of the thickness of the fly plate had a certain effect on the propagation velocity of the shock wave, and the increase of the peak pressure would make the cavitation generation position close to the fluid-structure interface and make the cavitation duration longer. And the average structure which has a minimum transformation of 8.12 mm shows better underwater impact resistance than the gradient structure. [ABSTRACT FROM AUTHOR]

[Display omitted] • Novel viscoelastic cell arrays are incorporated in a bicycle helmet liner. • Shear and compressive response of the cells are controlled via changing their curvature. • Significant improvements with the novel cell arrays over conventional EPS foam. • Shear-compliant cells can significantly reduce rotational kinematics and brain strain. • Placement of cells with varying amounts of shear stiffness should be optimised. Rotational head motion is one of the major contributors to brain tissue strain during head impacts, which damages axons and vessels and leads to traumatic brain injury. Helmet technologies have come to market promising enhanced protection against such rotational head motion. We recently introduced novel air-filled viscoelastic cell arrays and showed that their shear response under oblique impacts can be tailored through altering the cell wall curvature. We found that concave cells provide shear stiffness that is a few folds larger than that of convex cells. Here we test whether altering the cell curvature can reduce head rotational kinematics and brain strain and whether the viscoelastic cell arrays outperform the reference EPS foam-based liner. To test these hypotheses, we incorporate the viscoelastic cell arrays in a bicycle helmet liner. We use validated finite element models of the helmet and replace the liner with validated finite element models of the cellular cell arrays. We simulate oblique impacts at different locations to represent a wide range of real-world bicycle head impacts. In all cases, the head kinematics and brain deformation metrics indicate significant improvements with the novel cell arrays over the conventional EPS liner. We show that the shear-compliant cell arrays can reduce head rotational acceleration by as much as 64 % and brain strain by 69 %, but not in all impact locations. Cell arrays with similar axial stiffness yet lower shear stiffness often bottomed out, indicating that a considerable amount of energy is dissipated via cell shearing around the impact zone. Our results show that placement of cells with varying amounts of shear stiffness should be optimised, with the most shear-compliant cells near the crown and the least near the temples. This study shows the promising performance of viscoelastic cell arrays in protecting the head and brain under oblique impacts and provides avenues for optimising the distribution of their compressive-shear properties. [ABSTRACT FROM AUTHOR]

Auxetic lattice structures are known for their superior stiffness-to-density and strength-to-density ratios. Re-entrant hourglass exhibits an acceptable equivalent elastic modulus and remarkable energy absorption capacity among various auxetic configurations due to their flexibility and hinge deflecting during crushing loads. This study introduces a curved hourglass honeycomb which can be produced using 3D printing with pure or reinforced filaments incorporating continuous fibers. New closed-form formulations are analytically derived using an energy method by considering an extracted unit cell to predict the equivalent in-plane mechanical properties for the first time. The plateau stress of the proposed honeycomb is evaluated at the densification state of a unit cell using the energy conservation theory, equating external work with plastic energy dissipation. The accuracy of these extended relations is validated against experimental outcomes, demonstrating good agreement between analytical and experimental results. Additionally, robust linear and nonlinear finite element analyses are conducted to assess the accuracy of the obtained relations, including the equivalent stiffness and plateau stress for structures produced with reinforced filaments. The nonlinear finite element code employs appropriate subroutines to model plasticity/damage events. Based on the established analytical relations for stiffness and plateau stress, multi-objective optimization using Genetic Algorithm is applied to define optimum values for the Pareto front chart's objective functions of stiffness and plateau stress. The optimization process involves exploring the design space and defining the values of geometrical parameters to achieve the desired objectives. In conclusion, this study presents a novel approach to developing curved re-entrant honeycomb structures, with analytical formulations validated against experimental and numerical results. Optimization helps to identify optimal configurations concerning stiffness and plateau stress, offering potential applications in lightweight and high-strength materials design. According to the obtained results, for selection of the best value for curved strut angle which results in the optimum value of stiffness and plateau stress, a range between 10°-34° can be considered depending on the volume fraction of fibers. [ABSTRACT FROM AUTHOR]

Recently, auxetic metamaterials have turned into an area of growing interest, because of their deformation uniqueness, design flexibility, and functional diversity. To achieve their programmable design of densification and energy absorption, the variable stiffness factor method (VSF) emerged. However, the energy absorption capacity of the metamaterials designed by this method has a significant reduction. In this work, to remedy this defect, several different lightweight specimens are proposed and fabricated to extend the stage of energy absorption and retain the tunability. Then quasi-static compression tests and finite element methods are carried out to analyze the mechanical properties of the designed boundary-constrained structure (BCS) and X-shape constrained structure (XCS). The accuracy of the densification points and energy absorption capacity of the two structures at different VSF values are also studied. The results show that the densification points of the designed structures can be adjusted quantitatively, and their deformation modes are more stable than conventional structures during compression. Furthermore, their specific energy absorption is four and five times higher than that of non-lightweight structures with VSF = 40%, respectively. These findings contribute to advancing the implementation of auxetics in applications of multistage protective structures. • A lightweight metamaterial based on the variable stiffness factor (VSF) method is proposed. • The proposed structures realize multi-level energy absorption and stable deformation. • The SEA of proposed structures was 4 and 5 times higher than that of VSF = 40% structure. [ABSTRACT FROM AUTHOR]

Metamaterial structures that exhibit negative stiffness (MSNS) behavior have shown the potential to be used as energy dissipation systems in different applications. Negative stiffness honeycomb structures consist of multiple pre-buckled beams that snapping through from one pre-buckled mode to another buckled mode, when subjected to transverse loads, displaying negative stiffness, and dissipating a significant portion of the input energy. This paper presents finite element models (FEMs) developed to investigate the performance of negative stiffness pre-buckled beams and honeycombs. The FEMs were validated using experimental results of single pre-buckled beams and honeycomb structures. The experimental testing of the pre-buckled beams was presented in the current study while the results of the honeycomb were available in the literature. The FEMs have the ability to capture the transition of the elements from one mode of buckling to another mode as well as the force thresholds, energy dissipation values, and residual displacements. The FEMs were extended to investigate the effect of different parameters such as boundary condition, apex height-to-beam thickness ratio, and constraining the second mode of buckling on the behavior of negative stiffness honeycombs. • Metamaterial structures that exhibit negative stiffness (MSNS) have potential for use in energy dissipation systems. • Finite element models (FEMs) are presented to study the performance of MSNS beams and honeycombs. • FEMs are validated using experimental results from single pre-buckled beams and honeycomb structures. • FEMs can accurately predict transitions between different modes of buckling, force thresholds, and energy dissipation. [ABSTRACT FROM AUTHOR]

• Combining ML and FE methods to accelerate the design process of honeycomb structures. • Using 2D unit cell surrogate 3D honeycomb structures. • CDAE with a pixelation strategy is proposed to manage FE data. • LSTM uses latent features and external loads to predict structural dynamic responses. In this study, a novel framework was presented for accelerating the prediction of the mechanical response of honeycomb structures under dynamic crushing, using 2D cells to surrogate 3D honeycomb structures by machine learning (ML). The sizes of different honeycomb structures were designed and the necessary training data obtained through finite element (FE) simulations, but without using any explicit design parameters of the honeycomb cells in the ML model. A pixelization method of FE model was proposed to separate the complete cell structure from the honeycomb FE grid data and convert it into a matching pixel map. FE data was structuralized while reducing the large amount of computational power consumed in identifying complex array structures. Unsupervised automatic extraction of low-dimensional features of pixel maps was performed using a convolutional denoising autoencoder (CDAE). The crushing velocity and the extracted latent features were used as the input of the long-short term memory (LSTM) network to predict the crushing deformation and stress-strain curve of the honeycomb structure under different dynamic loading. Results showed that the constructed ML model could describe the dynamic crushing response behavior. Compared with the traditional FE method, the prediction model was 4.45 × 103 and 1.05 × 103 times faster in predicting the stress-strain and structural deformation response, respectively. The mechanical response prediction model provided a method for rapidly evaluating the dynamic mechanical response behavior of similar periodic array structures using FE model data, which could be beneficial for the design and development of equipment based on bionic structures. [ABSTRACT FROM AUTHOR]

Despite comprehensive prevention strategies, offshore operations consistently grapple with health, safety, and environmental (HSE) challenges. Though explosions on offshore structures are rare, their devastating impact cannot be understated. Blast walls, functioning as pivotal passive barriers, play a crucial role in protecting the topsides of these structures by dissipating explosive energy. Sandwich panel structures (SPS), with their lightweight attributes, enhanced bending rigidity and exceptional energy absorption, are a cost-effective countermeasure. This study introduces a groundbreaking design guideline, anchored in the LS-Dyna nonlinear finite-element method (NLFEM), tailored for hexagonal SPS offshore blast walls under explosive strains. Our rigorous numerical simulations, encompassing 450 varied scenarios, meticulously evaluated an array of geometric configurations and explosive strengths (spanning from 1 kg to 3 kg of TNT). From these simulations, crucial parameters affecting maximum mid-span plate deflection were discerned. In addition to these simulations, our research offers in-depth technical reviews, shedding light on the nuances of the subject. An empirical formula was subsequently formulated to anticipate this deflection, corroborating its efficacy by FE simulation outcomes. This work provides invaluable guidance for refining early-stage offshore blast wall design. • An in-depth technical reviews on the mechanical response of blast wall by sandwich panel system (SPS) is conducted. • A useful empirical formula is developed and can be utilised in the Pre-FEED stage in predicting the maximum deflection of the blast wall. • The proposed diagram may help to optimise the topside space of the offshore platform. [ABSTRACT FROM AUTHOR]

• A novel EARE is designed by introducing an elliptical annular into RE cell. • EARE produces extra vertical support without hindering lateral deformation. • EARE concurrently enhances auxetic performance, stiffness, and SEA. • Adjusting geometric parameters rationalizes designing mechanical properties. Auxetic structures have sparked a lot of interest due to their excellent mechanical characteristics and unusual negative Poisson's ratio influence. However, the large porosity property results in low stiffness, which limits their application scope. Current approaches to augment stiffness often result in diminished auxetic performance. Therefore, it is challenging to simultaneously enhance the auxetic, stiffness and energy absorption capacity of auxetic structures. To address this issue, this paper proposes a novel elliptical annular re-entrant honeycomb (EARE) by introducing an elliptical annular structure into a conventional re-entrant honeycomb (RE) cell, which can provide extra longitudinal support without hindering lateral deformation. The plateau stress, Poisson's ratio and energy absorption properties of the EARE are investigated by quasi-static compressive tests and finite element modeling. The results show that the EARE honeycomb has two plateau stages due to the supporting effect of the elliptical annular structure. Compared with the conventional RE honeycomb with the same wall thickness, the EARE honeycomb not only exhibits a stronger auxetic effect embodied in the Poisson's ratio reduced by 5.19%, but also has a higher average plateau stress and a higher specific energy absorption of 171.63% and 28.03%, respectively, which significantly improves the stiffness and energy absorption performance. The parameterized analysis reveals that by appropriately adjusting the geometric parameters, the stiffness, energy absorption, and auxetic effect of the EARE honeycomb can be enhanced. The research findings address the conflict between auxetic performance and honeycomb stiffness, providing new insights into the optimization of honeycomb structure design. [Display omitted] [ABSTRACT FROM AUTHOR]

• 3D bi-material triangle re-entrant honeycomb with adjustable Poisson's ratio is proposed. • The intrinsic mechanisms of tunable CTE and PR are revealed by theoretical models. • The finite element analysis is used to calculate the band structures and width of the total effective bandgap. • This work provides a design idea for 3D metamaterials to regulate CTE, PR and the bandgap. In the aerospace industry, precision components need to serve in a comprehensive environment of severe temperature changes, vibrations, and noise. Therefore, it is necessary to design a multifunctional mechanical metamaterial that integrates a tunable coefficient of thermal expansion (CTE), Poisson's ratio (PR), and bandgap. Here, a 3D bi-material triangle re-entrant honeycomb (3D-BTRH) with adjustable Poisson's ratio is proposed. Due to the geometric symmetry, the 3D-BTRH realizes the isotropy of mechanical properties in the three coordinate axes. The intrinsic mechanisms of tunable CTE and PR of the 3D-BTRH are revealed by building theoretical models. The accuracy of the theoretical analysis of PR and Young's modulus is verified by simulation and experiment. The finite element analysis is used to calculate the band structures and width of the total effective bandgap utilizing Bloch's theorem and Bloch's periodic boundary conditions. The accuracy of the band structure calculations is verified by calculating the transmission characteristic curve. The parametric analysis shows that the 3D-BTRH can achieve tunable CTE and PR in the directions of the three axes, and has a large width of the total effective bandgap. Moreover, this work provides a design idea for 3D metamaterials to simultaneously regulate CTE, PR, and the bandgap, which offers opportunities for better engineering practice. [Display omitted] [ABSTRACT FROM AUTHOR]