Publications

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Honeycomb is a structure that consists of two-dimensional regular arrays of open cells. High-density aluminum honeycomb has been used in weapon assemblies to mitigate shock and protect payload because of its excellent crush properties. In order to use honeycomb efficiently and to certify the payload is protected by the honeycomb under various loading conditions, a validated honeycomb crush model is required and the mechanical properties of the honeycombs need to be fully characterized. Volume I of this report documents an experimental study of the crush behavior of high-density honeycombs. Two sets of honeycombs were included in this investigation: commercial grade for initial exploratory experiments, and weapon grade, which satisfied B61 specifications. This investigation also includes developing proper experimental methods for crush characterization, conducting discovery experiments to explore crush behaviors for model improvement, and identifying experimental and material uncertainties.

A new constitutive model for large deformation of aluminum honeycomb has been developed. This model has 6 yield surfaces that are coupled to account for the orthotropic behavior of the cellular honeycomb being crushed on-axis and off-axis. Model parameters have been identified to fit uniaxial and biaxial crush test data for high density (38 1b/ft3) aluminum honeycomb. The honeycomb crush model has been implemented in the transient dynamic Presto finite element code for impact simulations. Simulations of calibration and validation experiments will be shown with model predictions compared with test data. Also, the honeycomb model's predictions will be compared with the older Orthotropic Rate Model predictions. Copyright © 2006 by ASME.

In order to create an analytical model of a material or structure, two sets of experiments must be performed-calibration and validation. Calibration experiments provide the analyst with the parameters from which to build a model that encompasses the behavior of the material. Once the model is calibrated, the new analytical results must be compared with a different, independent set of experiments, referred to as the validation experiments. This modeling procedure was performed for a crushable honeycomb material, with the validation experiments presented here. This paper covers the design of the validation experiments, the analysis of the resulting data, and the metric used for model validation.

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This report documents how active structural control was used to significantly enhance the metal removal rate of a milling machine. An active structural control system integrates actuators, sensors, a control law and a processor into a structure for the purpose of improving the dynamic characteristics of the structure. Sensors measure motion, and the control law, implemented in the processor, relates this motion to actuator forces. Closed-loop dynamics can be enhanced by proper control law design. Actuators and sensors were imbedded within a milling machine for the purpose of modifying dynamics in such a way that mechanical energy, produced during cutting, was absorbed. This limited the on-set of instabilities and allowed for greater depths of cut. Up to an order of magnitude improvement in metal removal rate was achieved using this system. Although demonstrations were very successful, the development of an industrial prototype awaits improvements in the technology. In particular, simpler system designs that assure controllability and observability and control algorithms that allow for adaptability need to be developed.