Hierarchical Energy Absorption and Dynamic Response of Bionic Thin-Walled-Foam Composite Structures Based on Mechanical Matching Design
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摘要: 针对轻质防护结构对稳定承载与高效能量吸收协同提升的需求，提出了一种基于力学匹配的混合仿生薄壁-泡沫复合结构设计方法。利用增材制造技术，制备了3种构型的聚乳酸（polylactic acid, PLA）仿生壳体，并通过原位发泡构建聚氨酯泡沫填充复合结构。通过拉伸试验、准静态压缩试验及动态落锤冲击试验，研究发泡过程产生的热效应对PLA壳体性能及复合结构力学响应的影响。通过峰值力、平台力、比吸能、平均压溃力、压溃力效率等指标对结构耐撞性能进行定量评价。结果表明，发泡导致的热效应降低了PLA的弹性模量和强度，并提高延展性，从而改善壳体与泡沫之间的力学匹配。复合结构的平台力和平均压溃力显著提升，压溃模式由局部失稳转变为渐进堆叠坍塌，表现出稳定的分级吸能特征。动态冲击试验进一步验证了结构在高能冲击作用下的稳定承载和吸能能力。研究结果揭示了几何构型、材料匹配与热-力耦合效应协同作用下的结构吸能机制，为轻质仿生防护结构的设计与优化提供了新的思路。Abstract: To achieve the synergistic improvement of load-bearing stability and energy absorption in lightweight protective structures, a bio-inspired thin-walled-foam composite structure based on mechanical matching design was proposed. Three configurations of polylactic acid (PLA) bio-inspired shells were fabricated via additive manufacturing, and subsequently filled with polyurethane foam through an in-situ foaming process. Tensile tests, quasi-static compression tests, and drop-weight impact tests were conducted to investigate the foaming-induced thermal effects on the mechanical properties of the PLA shells and the structural response of the composites. Crashworthiness was evaluated using peak crushing force (PCF), plateau force, specific energy absorption (SEA), mean crushing force (MCF), and crushing force efficiency (CFE). Results show that the temperature rise during foaming reduces the elastic modulus and strength of PLA while improving its ductility, thereby enhancing the mechanical compatibility between the shell and foam. Consequently, the composite structures exhibit significantly increased plateau force and MCF, and their collapse mode transforms from local instability to progressive stacked crushing, leading to stable hierarchical energy absorption. Dynamic impact tests further demonstrate the superior load-bearing and energy absorption performance of the composite structures under high-energy impact. The results highlight the synergistic role of geometric configuration, material matching, and thermal-mechanical coupling in regulating the energy absorption behavior, providing guidance for the design of lightweight bio-inspired protective structures.
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图 1 仿生复合结构设计示意图：(a) 马尾草和蜘蛛网结构[25–27]，(b) 3D打印的薄壁壳体，(c) 柚子皮结构及微观示意图[28]，(d) 聚氨酯试样及扫描电镜图像，(e) 基于混合仿生的复合结构实物
Figure 1. Schematic diagram of the biomimetic composite structure design: (a) marsh horsetail and spider web structures[25–27]; (b) 3D-printed thin-walled shells; (c) pomelo peel structure and microscopic schematic[28]; (d) polyurethane specimen and scanning electron microscope (SEM) images; (e) physical image of hybrid bionic composite structure
图 2 现场测试布局: (a) PLA试样的准静态拉伸测试，(b) 仿生结构的准静态压缩测试，(c)试样加热装置，(d) 动态落锤测试
Figure 2. Layout of on-site testing: (a) quasi-static tensile testing of PLA specimen; (b) quasi-static compression testing of biomimetic structures; (c) specimen heating apparatus; (d) dynamic drop-weight testing
图 3 PLA和PU基础材料的应力-应变曲线： (a) PLA试样在常温和加热工况下准静态拉伸的应力-应变曲线, (b) PU试样准静态压缩的应力-应变曲线
Figure 3. Stress-strain curves for PLA and PU: (a) stress-strain curves for quasi-static tensile testing of PLA specimens under ambient and heated conditions; (b) stress-strain curves for quasi-static compression testing of PU specimens
图 4 仿生结构的力-位移曲线：(a) 壳体结构在常温和加热工况下的力-位移曲线，(b) 复合结构的力-位移曲线
Figure 4. Force-displacement curves of biomimetic structures: (a) force-displacement curves of the shell structure under ambient and heated conditions; (b) force-displacement curves of the composite structures
图 5 仿生结构的耐撞性分析：(a) 峰值力和平台力，(b) 比吸能，(c) 平均压溃力，(d) 压溃力效率
Figure 5. Impact resistance analysis of the biomimetic structure: (a) peak crushing force and plateau force; (b) specific energy absorption; (c) average crushing force; (d) crushing force efficiency
图 6 仿生结构在准静态压缩下的宏观失效形式
Figure 6. Macro-scale failure modes of biomimetic structures under quasi-static compression
图 7 仿生结构在低速落锤冲击下的力-位移曲线
Figure 7. Force-displacement curves of the biomimetic structures under low-velocity impact
表 1 6种仿生结构及其参数
Table 1. Parameters of six bionic structures
Sample type Structure Parameters Physical mass/g PLA-C2 
R1=40.92 mm
R2=20.46 mm
t1=1.50 mm42.1±0.20 PLA-H2 
l1=45.00 mm
l2=22.50 mm
t2=1.42 mm44.9±0.25 PLA-CH 
R1=40.92 mm
l2=22.50 mm
t1=1.50 mm43.2±0.10 PLA-C2-PU200 
ρPU=200 kg/m3 70.9±0.10 PLA-H2-PU200 
ρPU=200 kg/m3 72.6±0.12 PLA-CH-PU200 
ρPU=200 kg/m3 70.7±0.35 
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