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The purpose of this paper is to carry out a series of transient, non‐linear dynamics finite element analyses in order to investigate the interactions between a stereotypical pneumatic tire and sand during off‐road vehicle travel.

The interactions were considered under different combined conditions of the longitudinal and lateral slip as encountered during “brake‐and‐turn” and “drive‐and‐turn” vehicle maneuvers. Different components of the pneumatic tire were modeled using elastic, hyper‐ and visco‐elastic material models (with rebar reinforcements), while sand was modeled using the CU‐ARL sand models developed by Grujicic et al. The analyses were used to obtain functional relations between the wheel vertical load, wheel sinkage, tire deflection, (gross) traction, motion resistance and the (net) drawbar pull. These relations were next combined with Pacejka magic formula for a pneumatic tire/non‐deformable road interaction to construct a tire/sand interaction model suitable for use in multi‐body dynamics analysis of the off‐road vehicle performance.

To rationalize the observed traction and motion resistance relations, a close examination of the distribution of the normal and shear contact stresses within the tire/sand contact patch is carried out and the results were found to be consistent with the experimental counter parts.

The paper offers insights into the interactions between a stereotypical pneumatic tire and sand during off‐road vehicle travel.

The purpose of this paper is to compare fracture‐fixation and bone‐healing promotion efficacies of an intramedullary (IM) nail‐type and an external osteosynthesis plate‐type femoral trochanteric‐fracture implants using the results of a combined multi‐body dynamics and finite element analyses. For both implants, fracture fixation was obtained using a dynamic hip blade which is anchored to the femur head on one end and is connected to the IM rod/plate on the other. The analysis was carried out for two pre‐fracture conditions of the femur: healthy and osteoporotic.

The musculoskeletal dynamics portion of the analysis was used to obtain realistic physiological loading conditions (i.e. muscle forces and joint reaction forces and moments) associated with four typical everyday activities of a patient, namely, walking, lunging, cycling and egress (i.e. exiting a passenger vehicle). The subsequent structural finite element analysis of the fractured femur/implant assembly was employed to quantify fracture‐fixation efficacy (as measured by the extents of lateral (found to be minor), flexural and torsional displacements of the two femur fragments) and the bone‐healing promotion efficacy (as quantified by the fraction of the fractured surface area which experienced desirable contact pressures).

The results obtained show that, in general, the IM‐rod type of implant out‐performs the osteosynthesis plate type of implant over a large range of scenarios involving relative importance of the bone‐healing promotion and fracture‐fixation efficacies, health condition of the femur and the activity level of the patient. More specifically, the more active the patient and the larger extent of osteoporosis in the femur, the more justifiable is the use of the IM‐rod type of implant.

The present approach enables assessment of the fracture‐fixation performance of orthopedic implants under physiologically realistic loading conditions.

A parallel finite‐element/multi‐body‐dynamics investigation is carried out of the effect of up‐armoring on the off‐road performance of a prototypical high‐mobility multipurpose‐wheeled vehicle (HMMWV). The paper seeks to investigate the up‐armoring effect on the vehicle performance under the following off‐road maneuvers: straight‐line flatland braking; straight‐line off‐angle downhill braking; and sharp left turn.

For each of the above‐mentioned maneuvers, the appropriate vehicle‐performance criteria are identified and the parameters used to quantify these criteria are defined and assessed. The ability of a computationally efficient multi‐body dynamics approach when combined with a detailed model for tire/soil interactions to yield results qualitatively and quantitatively consistent with their computational counterparts obtained using computationally quite costly finite element analyses is assessed.

The computational results obtained clearly reveal the compromises in vehicle off‐road performance caused by the up‐armoring employ to improve vehicle blast and ballistic protection performance/survivability. The results obtained are also analyzed and explained in terms of general field‐test observations in order to judge physical soundness and fidelity of the present computational approaches.

The paper offers insights into the effects of up‐armoring of the HMMWV on off‐road vehicle performance.

The purpose of this paper is to propose and analyse computationally a new concept for mechanical interlocking between metal and plastics. The approach utilizes some of the ideas used in the spot‐clinching joining process and is appropriately named “clinch‐lock polymer metal hybrid (PMH) technology.”

A new approach, the so‐called “direct‐adhesion” PMH technology, is recently proposed Grujicic et al. to help meet the needs of automotive original equipment manufacturers and their suppliers for a cost‐effective, robust, reliable PMH technology which can be used for the manufacturing of load‐bearing body‐in‐white (BIW) components and which is compatible with the current BIW manufacturing‐process chain. Within this approach, the necessary level of polymer‐to‐metal mechanical interconnectivity is attained through direct adhesion and mechanical interlocking.

In an attempt to fully assess the potential of the clinch‐lock approach for providing the required level of metal/polymer mechanical interlocking, a set of finite‐element based sheet‐metal forming, injection molding and structural mechanics analyses is carried out. The results obtained show that stiffness and buckling resistance levels can be attained which are comparable with those observed in the competing injection over‐molding PMH process but with an ∼3 percent lower weight (of the polymer subcomponent) and without the need for holes and for over‐molding of the free edges of the metal stamping.

The paper presents a useful discussion of clinch‐lock joining technology's potential for fabrication of PMH load‐bearing BIW components.

Among various efforts pursued to produce fuel efficient vehicles, light weight engineering (i.e. the use of low‐density structurally‐efficient materials, the application of advanced manufacturing and joining technologies and the design of highly‐integrated, multi‐functional components/sub‐assemblies) plays a prominent role. In the present work, a multi‐disciplinary design optimization methodology has been presented and subsequently applied to the development of a light composite vehicle door (more specifically, to an inner door panel). The door design has been optimized with respect to its weight while meeting the requirements /constraints pertaining to the structural and NVH performances, crashworthiness, durability and manufacturability. In the optimization procedure, the number and orientation of the composite plies, the local laminate thickness and the shape of different door panel segments (each characterized by a given composite‐lay‐up architecture and uniform ply thicknesses) are used as design variables. The methodology developed in the present work is subsequently used to carry out weight optimization of the front door on Ford Taurus, model year 2001. The emphasis in the present work is placed on highlighting the scientific and engineering issues accompanying multidisciplinary design optimization and less on the outcome of the optimization analysis and the computational resources/architecture needed to support such activity.

Application of the engineering design optimization methods and tools to the design of automotive body‐in‐white (BIW) structural components made of polymer metal hybrid (PMH) materials is considered. Specifically, the use of topology optimization in identifying the optimal initial designs and the use of size and shape optimization techniques in defining the final designs is discussed. The optimization analyses employed were required to account for the fact that the BIW structural PMH component in question may be subjected to different in‐service loads be designed for stiffness, strength or buckling resistance and that it must be manufacturable using conventional injection over‐molding. The paper demonstrates the use of various engineering tools, i.e. a CAD program to create the solid model of the PMH component, a meshing program to ensure mesh matching across the polymer/metal interfaces, a linear‐static analysis based topology optimization tool to generate an initial design, a nonlinear statics‐based size and shape optimization program to obtained the final design and a mold‐filling simulation tool to validate manufacturability of the PMH component.

In the recent work, a new blast-wave impact-mitigation concept involving the use of a protective structure consisting of bimolecular reactants (polyvinyl pyridine+cyclohexyl chloride), capable of undergoing a chemical reaction (to form polyvinyl pyridinium ionic salt) under shockwave loading conditions, was investigated using all-atom reactive equilibrium and non-equilibrium molecular-dynamics analyses. The purpose of this paper is to reveal the beneficial shockwave dispersion/attenuation effects offered by the chemical reaction, direct simulations of a fully supported single planar shockwave propagating through the reactive mixture were carried out, and the structure of the shock front examined as a function of the extent of the chemical reaction (i.e. as a function of the strength of the incident shockwave). The results obtained clearly revealed that chemical reactions give rise to considerable broadening of the shockwave front. In the present work, the effect of chemical reactions and the structure of the shockwaves are investigated at the continuum level.

Specifically, the problem of the (conserved) linear-momentum accompanying the interaction of an incident shockwave with the protective-structure/protected-structure material interface has been investigated, within the steady-wave/structured-shock computational framework, in order to demonstrate and quantify an increase in the time period over which the momentum is transferred and a reduction in the peak loading experienced by the protected structure, both brought about by the occurrence of the chemical reaction (within the protective structure).

The results obtained clearly revealed the beneficial shock-mitigation effects offered by a protective structure capable of undergoing a chemical reaction under shock-loading conditions.

To the authors’ knowledge, the present manuscript is the first report dealing with a continuum-level analysis of the blast-mitigation potential of chemical reactions.

This paper aims to conduct a combined Eulerian/Lagrangian fluid/solid transient non‐linear dynamics computational analysis of the interaction between a single planar blast wave and a human head in order to assess the extent of intra‐cranial shock wave generation and its potential for causing traumatic brain injury.

Two levels of blast peak overpressure were selected, one corresponding to the unprotected lung‐injury threshold while the other associated with a 50 percent probability for lung injury caused death. Collision of the head with a stationary/rigid barrier (at an initial collision velocity of 5 m/s) was also analyzed computationally, since blunt‐object impact conditions may lead to mild traumatic brain injury (mTBI), i.e. concussion.

A comparison between the two blast and the single blunt‐object impact cases with the corresponding head‐to‐head‐collision results showed that, while the von Mises stress‐based head‐to‐head collision mTBI thresholds are not exceeded under blast‐loading conditions investigated, the high blast‐induced peak‐pressure levels within the intra‐cranial cavity may lead to mTBI.

While concussion is not generally considered as life altering/threatening, the associated temporary loss of situational awareness or consciousness may have devastating consequences in the case of common military tactical and battle‐field scenarios. This suggests that the head‐protection gear (primarily, the helmet) which are currently designed to withstand blunt‐object and ballistic impacts, should be redesigned in order to obtain the necessary level of head protection with respect to blast impact.

The paper provides a comprehensive computational investigation of impact on a human skull/brain assembly.

Polyurea falls into a category of elastomeric co‐polymers in which, due to the presence of strong hydrogen bonding, the microstructure is of a heterogeneous nature and consists of a compliant/soft matrix and stiff/hard nanometer size hard domains. Recent investigations have shown that the use of polyurea as an external or internal coating/lining had substantially improved ballistic‐penetration resistance of metallic structures. The present work aims to use computational methods and tools in order to assess the shock‐mitigation ability of polyurea when used in the construction of different components (suspension‐pads, internal lining and external coating) of a combat helmet.

Shock‐mitigation capability of combat helmets has become an important functional requirement as shock‐ingress into the intra‐cranial cavity is known to be one of the main causes of traumatic brain injury (TBI). To assess the shock mitigation capability of polyurea, a combined Eulerian/Lagrangian fluid/solid transient non‐linear dynamics computational analysis of an air/helmet/head core sample is carried out and the temporal evolution of the axial stress and particle velocities (for different polyurea augmented helmet designs) are monitored.

The results obtained show that improvements in the shock‐mitigation performance of the helmet are obtained only in the case when polyurea is used as a helmet internal lining and that these improvements are relatively small. In addition, polyurea is found to slightly outperform conventional helmet foam, but only under relatively strong (greater than five atm) blastwave peak overpressures.

The present approach studies the effect of internal linings and external coatings on combat helmet blast mitigation performance.

The purpose of this paper is to discuss the recently developed multi-physics computational model for the conventional Gas Metal Arc Welding (GMAW) joining process that has been upgraded with respect to its predictive capabilities regarding the spatial distribution of the mechanical properties controlling the ballistic limit (i.e. penetration resistance) of the weld.

The original model consists of five modules, each dedicated to handling a specific aspect of the GMAW process, i.e.: electro-dynamics of the welding-gun; radiation-/convection-controlled heat transfer from the electric arc to the workpiece and mass transfer from the filler-metal consumable electrode to the weld; prediction of the temporal evolution and the spatial distribution of thermal and mechanical fields within the weld region during the GMAW joining process; the resulting temporal evolution and spatial distribution of the material microstructure throughout the weld region; and spatial distribution of the as-welded material mechanical properties. The model is upgraded through the introduction of the sixth module in the present work in recognition of the fact that in thick steel GMAW weldments, the overall ballistic performance of the armor may become controlled by the (often inferior) ballistic limits of its weld (fusion and heat-affected) zones.

The upgraded GMAW process model is next applied to the case of butt-welding of MIL A46100 (a prototypical high-hardness armor-grade martensitic steel) workpieces using filler-metal electrodes made of the same material. The predictions of the upgraded GMAW process model pertaining to the spatial distribution of the material microstructure and ballistic-limit-controlling mechanical properties within the MIL A46100 butt-weld are found to be consistent with general expectations and prior observations.

To the authors’ knowledge, the present work is the first reported attempt to establish, using computational modeling, functional relationships between the GMAW process parameters and the mechanical properties controlling the ballistic limit of the resulting weld.