Quasi-static bending of thin-walled beams with different fillers under extreme load for solving the problems of crashworthiness

In this paper, there are issues related to the choice of elemental modelling of thin-walled beams with various types of fillers for quasi-static bending loading, which causes washing of beams and filler, as applied to the optimal design. The objects of research are thin-walled beams made of aluminium AMG6 contains fillers made of aluminium foam, epoxy resin and composite (consisting of Poraver balls and epoxy resin). One of the best fillers for solving the problems of crashworthiness is requiring expensive technological equipment for filling. Epoxy resin is a fragile material, but inexpensive, affordable and technologically “convenient”. In addition to the influence of the filler on the mechanical properties of beams, the effects of the constrained behaviour of the material of the filler under the bending loading of beams are investigated with Zwick Z100 (for hollow thin-walled beams made of aluminium and the same beams with fillers).The paper presents the results of numerical calculations and the results of the experiment (the error of calculations does not exceed 8%).The most rational is the ratio between the indicators of energy intensity - the mass is aluminium-foam (with an increase in the mass of the sample by 2,1 times the mechanical properties reach 10 of times). The remaining fillers give significantly worse results for the same parameters. To assess the effectiveness of the use and creation materials for the refinement of the cabins and car bodies according to the crashworthiness.