Energy Absorption
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Engineered Honeycomb Solutions and Services Energy Absorption A guide to kinetic energy management systems

What’s in this Guide • What is an Energy Absorber? Energy Absorption Terminology Types of Plascore Energy Absorbers Example: Drop Protection Example: Damping Impact Protection Large Mass Drop Protection Overrun Protection Nuclear Industry Compliance Crash Test Dummy Calibration Blast Mitigation Plascore Energy Absorption | Web: plascore.com | Email: sales@plascore.

What is an Energy Absorber? Energy Absorbed Crush Distance “The basic concept of energy absorption is to take a moving object’s kinetic energy and convert it into internal work.” When a load is applied to the honeycomb it exhibits plastic deformation, in the form of crushing. This deformation results in a constant force through the crushed thickness. The work (Force x Distance) done by the energy absorber defines how much kinetic energy the system has absorbed. Bitzer T. (1997). Honeycomb Technology Materials, Design, Manufacture, Applications and Testing. Great Britain: Chapman & Hall....

Energy Absorption Terminology Below is a sample graph (using data from pre-crushed 320 PSI Crush Core) that explains the basic terminology of Plascore’s energy absorbers. 320 PSI Crush Core (Pre-crushed) 1. Kinetic Energy Absorbed: Defined as the work (force x distance) done. 2. Crush Strength Tolerance: The acceptable range the average crush strength can be. 3. Crush Strength: Defined in accordance to ASTM D7336 as the average compressive stress during the core’s stable crush strength region. 4. Crush Stroke: The length a part is crushed. 5. Densification: Occurs when all material has been...

Types of Plascore Energy Absorbers Plascore manufactures two different materials that are ideal for energy absorption applications. The first of these is CrushLite, a lower density expanded aluminum honeycomb. The second is AlTuCore, a high-density corrugated material. Typically manufactured in 4’ x 8’ sheets Customer specified thicknesses Crush strengths ranging from 7.5 – 750 psi Can be provided with or without pre-crush Typical thickness range: 1” – 30” Minimum stroke of 70% of part thickness. Standard* crush strength ranges: Density Cell Size Foil Gauge Foil Alloy Cell Size Foil Gauge...

Example: Drop Protection The Problem: An engineer has been tasked with arresting a large tensioning weight used on an industrial conveyor belt. The tensioning weight poses a significant risk to equipment if it is allowed to plunge to the ground. Maximum Load on Support Structure Required Crush Strength Usable Support Structure Width Required Material Usable Support Structure Length Required Part Thickness Maximum Drop Height Mass of Tension Weight Determine required part thickness: Determine required crush strength to maximize load distribution. Governing equation Potential Energy (PE) =...

Example: Damping The Problem: An engineer is designing an amusement park ride and has the responsibly of ensuring the safety of the occupants. In this case the engineer is designing for a catastrophic cart-to-cart impact, and needs to ensure that the occupants are able to safely walk away. Based upon the usable area, the AlTuCore OD and ID have been predefined. Maximum Allowed “G” Load Required Stroke Cart Mass AlTuCore Outside Diameter AlTuCore Inside Diameter Part Length Required for Safe Deceleration Required Part Thickness Worst-Case Cart Velocity Crush Strength Step 1: Determine the...

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