Title: Dynamic axial crushing of multilayer core structures of folded Chevron patterns

Authors: Basily B. Basily, E.A. Elsayed

Addresses: Department of Industrial and Systems Engineering, Rutgers University, 96 Frelinghuysen Road, Piscataway, NJ 08854-8018, USA. ' Department of Industrial and Systems Engineering, Rutgers University, 96 Frelinghuysen Road, Piscataway, NJ 08854-8018, USA

Abstract: The objective of this paper is to investigate our recently developed innovative sheet folding theory and manufacturing processes in designing impact energy absorbing structures with superior properties to existing structures, such as honeycomb, while achieving a volume reduction of between 40 and 50%. Initial results indicate that we can mathematically generate three-dimensional patterns and use our folding technology to produce such patterns by simply folding flat sheets of materials, resulting in significant cost savings. The three-dimensional patterns, folded from different sheet materials, can be used as cores for laminated structures for impact energy absorption applications, such as in high speed airdrops of heavy items and in improving crash worthiness of vehicle body and bumpers. The results of testing samples of the Chevron patterns (the simplest to fold from flat sheets) indicate that core structures made from this pattern will serve as absorbers of high velocity impact energy per unit volume when compared with the well known and typically used honeycomb structures.

Keywords: folding geometry; high speed airdrop; honeycomb; impact energy absorption; Kraft paper; lamination; plastic hinge; sandwich structures; sheet material folding; tessellation; Chevron pattern structures.

DOI: 10.1504/IJMPT.2004.004750

International Journal of Materials and Product Technology, 2004 Vol.21 No.1/2/3, pp.169 - 185

Published online: 14 Jun 2004 *

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