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<p>Thin-walled hemispherical shell structures are commonly used as passive systems in the aviation industry due to their excellent energy-absorbing capacity (EAC) and lightweight nature. Thin walls are sensitive to imperfections, which can cause buckling, reduce stability, and decrease energy absorption capacity. To address these issues, this study presents two innovative designs: the Inter-Nested Hemispherical Shell Structure (INHSS) and the Polyurethane Foam-filled Hemispherical Shell Structure (PFHSS). These structures are evaluated under axial static and impact loading. The shell was designed with diameters of 80&#xa0;mm, 120&#xa0;mm, 160&#xa0;mm, and 200&#xa0;mm, utilizing various thickness configurations. These configurations included monolithic layers with thicknesses of 0.5&#xa0;mm, 1.0&#xa0;mm, 1.5&#xa0;mm, and 2&#xa0;mm, as well as double layers (0.5/0.5&#xa0;mm, 0.5/1.0&#xa0;mm, and 1.0/0.5&#xa0;mm). ABAQUS/CAE® was employed to develop numerical models that simulated the crash responses of monolithic shell structures (MSS) (INHSS) and PFHSS. The numerical results were verified against experimental results and existing literature. The findings revealed that the energy absorption capacity of PFHSS is superior to that of similar configurations in both monolithic and INHSS designs. Furthermore, the performance of the PFHSS structure is based on the deformation mode, whether dimple or flat. Notably, the EAC of the hemispherical sandwich structure in dimpling mode is lower than that in flat mode, even with a similar configuration. By altering the thicknesses of the outer and inner shells, the deformation mode can be shifted from dimpled to flat, which is an effective method to enhance energy absorption performance. These results offer valuable insights for developing improved energy crash absorbers in the aerospace and aviation industries with optimized configurations.</p>

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Dynamic response and energy absorption comparison between inter-nested and foam-filled hemispherical sandwich shell structures during impact

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • M. Nalla Mohamed

摘要

Thin-walled hemispherical shell structures are commonly used as passive systems in the aviation industry due to their excellent energy-absorbing capacity (EAC) and lightweight nature. Thin walls are sensitive to imperfections, which can cause buckling, reduce stability, and decrease energy absorption capacity. To address these issues, this study presents two innovative designs: the Inter-Nested Hemispherical Shell Structure (INHSS) and the Polyurethane Foam-filled Hemispherical Shell Structure (PFHSS). These structures are evaluated under axial static and impact loading. The shell was designed with diameters of 80 mm, 120 mm, 160 mm, and 200 mm, utilizing various thickness configurations. These configurations included monolithic layers with thicknesses of 0.5 mm, 1.0 mm, 1.5 mm, and 2 mm, as well as double layers (0.5/0.5 mm, 0.5/1.0 mm, and 1.0/0.5 mm). ABAQUS/CAE® was employed to develop numerical models that simulated the crash responses of monolithic shell structures (MSS) (INHSS) and PFHSS. The numerical results were verified against experimental results and existing literature. The findings revealed that the energy absorption capacity of PFHSS is superior to that of similar configurations in both monolithic and INHSS designs. Furthermore, the performance of the PFHSS structure is based on the deformation mode, whether dimple or flat. Notably, the EAC of the hemispherical sandwich structure in dimpling mode is lower than that in flat mode, even with a similar configuration. By altering the thicknesses of the outer and inner shells, the deformation mode can be shifted from dimpled to flat, which is an effective method to enhance energy absorption performance. These results offer valuable insights for developing improved energy crash absorbers in the aerospace and aviation industries with optimized configurations.