Finite element analysis of closed-cell aluminum foam approximated with Weaire-Phelan unit cell structure

Abstract

Abstract The finite element modelling of metal foam structures have proven to be a difficult task. Many different modelling approaches exist, both for creating the CAD model and for performing the finite element simulations. This article details the CAD and finite element modelling of an existing aluminum foam. To model the cell structure, the Weaire-Phelan unit cell was used. The different parameters of the unit cell were adjusted to fit the parameters of the existing foam. The physical properties of the finished model were then compared to the original specimen to validate its accuracy. After the comparison, it was determined, that the Weaire-Phelan unit cell can be used to model the physical properties of the structure. The validated and simplified model was then used to perform a finite element analysis under compressive loading. The results were compared to the compression test results of the existing aluminum foam. By comparing the results and calculating the relative errors, it was determined that both the physical and the mechanical properties of metal foam structures can be modelled using this exact method with significant accuracy.