Partitioning of elastic energy in open-cell foams under finite deformations

The challenges associated with the computational modeling and simulation of solid foams are threefold namely, the proper representation of an intricate geometry, the capability to accurately describe large deformations, and the extremely arduous numerical detection and enforcement of self-contact during crushing. The focus of this study is to assess and accurately quantify the effects of geometric nonlinearities (i.e. finite deformations, work produced under buckling-type motions) on the predicted mechanical response of open-cell foams of aluminum and polyurethane prior to the onset of plasticity and contact. Beam elements endowed with three-dimensional finite deformation kinematics are used to represent the foam ligaments. Ligament cross-sections are discretized through a fiber-based formulation that provides accurate information regarding the onset of plasticity, given the uniaxial yield stress strain data for the bulk material. It is shown that the (hyper-) elastic energy partition within ligaments is significantly influenced by kinematic nonlinearities, which frequently cause strong coupling between the axial, bending, shear and torsional deformation modes. This deformation mode-coupling is uniquely obtained as a result of evaluating equilibrium in the deformed configuration, and is undetectable when small deformations are assumed. The relationship between the foam topology and energy partitioning at various stages of moderate deformation is also investigated. Coupled deformation modes are shown to play an important role, especially in perturbed Kelvin structures where over 70% of the energy is stored in coupled axial-shear and axial-bending modes. The results from this study indicate that it may not always be possible to accurately simulate the onset of plasticity (and the response beyond this regime) if finite deformation kinematics are neglected. (C) 2012 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.