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Experimental Mechanics (2011) 51:1395–1403

DOI 10.1007/s11340-011-9466-3

Characterization of Anisotropic Polymeric Foam


Under Static and Dynamic Loading
I.M. Daniel & J.-M. Cho

Received: 8 September 2010 / Accepted: 13 January 2011 / Published online: 19 February 2011
# Society for Experimental Mechanics 2011

Abstract An orthotropic polymeric foam with transverse Young’s modulus of the foam was in very good agreement
isotropy (Divinycell H250) used in composite sandwich with the present and published experimental results.
structures was characterized at various strain rates. Uniaxial
experiments were conducted along principal material Keywords Cellular materials . Polymeric foams .
axes as well as along off-axis directions under tension, Mechanical characterization . Dynamic testing . Effects
compression, and shear to determine engineering con- of strain rate
stants, such as Young’s and shear moduli. Uniaxial strain
experiments were conducted to determine mathematical
stiffness constants, i. e., Cij. An optimum specimen aspect Introduction
ratio for these tests was selected by means of finite
element analysis. Quasi-static and intermediate strain rate In many applications, composite sandwich structures
tests were conducted in a servo-hydraulic testing machine. with polymeric foam cores are exposed to static, impact
High strain rate tests were conducted using a split and blast loadings producing multi-axial states of stress.
Hopkinson Pressure Bar system built for the purpose A great deal of work is being reported by investigators
using polymeric (polycarbonate) bars. The polycarbonate dealing with analysis and simulation of the response of
material has an impedance that is closer to that of foam composite sandwich structures under extreme loading
than metals and results in lower noise to signal ratios and conditions. The validity of the results obtained depends
longer loading pulses. It was determined by analysis and on the type of loading and material behavior inputs
verified experimentally that the loading pulses applied, used. Loading parameters may be obtained from the
propagated along the polycarbonate rods at nearly constant literature. However, no realistic models are available for
phase velocity with very low attenuation and dispersion. the facesheet and core materials under multi-axial static
Material properties of the foam were obtained at three strain or dynamic loading, especially models including non-
rates, quasi-static (10−4 s−1), intermediate (1 s−1), and high linear elastoplastic deformations. Characterization and
(103 s−1) strain rates. A simple model proposed for the modeling of facesheet composite materials under static
and dynamic loadings and multi-axial states of stress is
being addressed and reported in many sources. Howev-
er, there is need for more systematic characterization
I.M. Daniel (*, SEM fellow)
and constitutive modeling of structural foams used in
Robert R. McCormick School of Engineering and Applied
Science, Northwestern University, sandwich construction. Characterization of the mechan-
Evanston, IL 60208, USA ical behavior of cellular foam materials is essential for
e-mail: imdaniel@northwestern.edu their efficient use in sandwich structures and to develop
numerical models capable of capturing the static and
J.-M. Cho
Hyundai Motor Company, dynamic response of composite sandwich structures
Seoul, Korea under realistic loadings.
1396 Exp Mech (2011) 51:1395–1403

Fig. 3 Uniaxial compressive stress experiments

Fig. 1 Cell morphology of Divinycell H250 foam (scale bar is 1 mm) the PVC polymer [5]. Gdoutos et al. [6] and Deshpande et
al. [7] discussed multi-axial characterization of foams
Cellular materials or foams afford a means of optimizing including failure criteria. Additional quasi-static character-
the mechanical and thermal properties of structures with a ization studies including yield and failure criteria have been
minimum weight. They are commonly used as core discussed by Fiedler et al. [8], Abrate [9], and Flores-
materials in lightweight sandwich structures with high Johnson and Li [10]. Kanny et al. [11] and Zenkert et al.
strength, stiffness and impact damage tolerance and they [12] characterized polymeric foams under static and cyclic
play a critical role in the failure of sandwich structures loading and studied the failure mechanisms.
[1, 2]. The macroscopic behavior of foams is a function of Some foam materials, such as PVC foams (especially
the basic cell wall material and the cell microstructure. higher density ones), are strain rate dependent, anisotropic,
Polymeric foams are usually made of polyvinyl chloride and elastic/viscoplastic materials. Their deformation history
(PVC), polyurethane (PUR) or polystyrene. The mechanical during dynamic loading affects critically the integrity and
behavior of cellular foams has been investigated and functionality of the sandwich structure. Several studies
discussed extensively in the literature over the last two have been reported on dynamic characterization of foams
decades [3–15]. In most cases the emphasis is on the energy and the effect of strain rate [13–20]. Zhang et al. studied
absorption characteristics of foams undergoing large dy- strain rate and temperature effects under large deformations
namic deformations. A thorough discussion of polymeric [14]. They conducted uniaxial compression, hydrostatic
foams, including simple models for predicting mechanical compression and shear tests and proposed an elastoplastic
properties, is given in the classical work by Gibson and constitutive model. Their study was limited to low strain
Ashby [3]. Models have been proposed for estimating the
modulus and yield strength in terms of the density of the
foam and properties of the bulk material [3–5]. Liu and
Scanlon proposed a model for Young’s modulus in terms of
relative densities and geometrical parameters of the cell [4].
Lim et al. proposed models for open- and closed-cell PVC
foams and related the behavior to the molecular structure of

3
2
3-axis

1-axis

Fig. 2 Principal material axes and off-axis testing of Divinycell H250


foam Fig. 4 Uniaxial and shear strain experiments
Exp Mech (2011) 51:1395–1403 1397

Fig. 6 Schematic for pure shear


rates (up to 4.45 s−1). Daniel and Rao characterized experiments 1
isotropic and anisotropic foams at strain rates up to 800
s−1 [15]. They used a Hopkinson bar system with polymeric
(polycarbonate) rods for the high strain rate tests. Avalle et
al. conducted static and dynamic tests to determine the
energy absorption characteristics of structural foams [16]. 3
Ouellet et al. conducted tests over a wider range of strain
rates (0.0087–2,500 s−1) and modeled the strain rate
behavior [18]. More recent studies by Tagarielli et al. [19]
and Lee et al. [20] also covered a wide range of strain rates.
Constitutive modeling over the wide range of strains
experienced by foams has lagged because of the finite
deformations and the anisotropy involved in some foams,
with few works reported in the literature [14, 21, 22].
Gielen [22] developed a constitutive model including
elastic-plastic behavior and damage progression. Consider- scopic characterization of cellular foams is a challenging
ing the loading-unloading-reloading test results in [10], a problem because of their hyperelastic behavior and tenden-
different modeling approach is needed based on an elastic- cy for deformation localization due to local collapse of cells
plastic-damage formulation in strain space. under compression [23]. Some of the difficulties can be
This paper describes quasi-static and dynamic character- overcome by using stress-controlled and strain-controlled
ization of an anisotropic PVC foam and generates a set of experiments and full-field strain measurement methods. A
properties suitable for implementation in numerical studies more complete characterization of this material was
of composite sandwich structures. Uniaxial stress and performed by means of static and high rate tests along
uniaxial strain experiments were conducted. Multi-axial principal material axes as well as off-axis directions under
behavior was characterized by means of of-axis tests. tension, compression, and shear (at orientations of 0, 20,
Models for prediction of Young’s modulus are discussed 45, 70, and 90 deg with the 3-axis, Fig. 2). Three to five
and a simplified model is proposed. tests were conducted in each case to insure reproducibilty.
Uniaxial stress experiments in tension or compression,
require coupons with a high enough aspect ratio and/or
Experimental Procedures frictionless contact between the specimen ends and the
loading blocks. Because of the difficulties mentioned
The material studied was a closed cell PVC foam, before, it is desirable to use full-field optical techniques,
Divinycell H250 (DIAB Inc.). All specimens in this study such as Moiré or Digital Image Correlation. In the tests
were obtained from one 25 mm thick panel having a conducted here, strains were measured by means of Moiré
uniform density of 248.8 kg/m3, close to the nominal one of gratings photoprinted on the specimen surface (Fig. 3).
250 kg/m3. The cell microstructure is shown in Fig. 1. On a These tests yield the principal Young’s moduli, E1 = E2,
macroscopic scale, the material is orthotropic/transversely and E3, and Poisson’s ratios, v12, v31 = v32. However, under
isotropic with principal axes as shown in Fig. 2. Macro- compressive loading, these tests do not yield the stress-
strain behavior faithfully beyond the apparent yield point
Aspect Ratio ε1 ≅ 0 because of localized crushing at the ends.
3
ε 3 = 1% Aspect Ratio γ 13 ≅ 1%
5 3
1
ε1 ≅ 0 5 γ 13 = 1%
1
8
γ 13 ≅ 1%
ε1 ≅ 0
10
10
γ 13 ≅ 1%
ε1 ≅ 0
20
20
stress concentration
Fig. 5 Selection of specimen aspect ratio for strain-controlled
compression tests Fig. 7 Selection of specimen aspect ratio for shear tests
1398 Exp Mech (2011) 51:1395–1403

Fig. 8 Split Hopkinson pressure specimen


bar with polymeric (polycarbonate)
bars for testing foam materials
striker bar incident bar transmitter bar

The problem of localized end crushing can be alleviated and the strains are
by using thin foam plate specimens constrained between
d
metal blocks as shown in Fig. 4 and loaded under g 13 ¼ sin1 and "3 ¼ 1  cos g 13 ð4Þ
controlled strain. Such experiments were conducted at t
quasi-static and moderate strain rates of 10−4 and 1 s−1. High strain rate properties require testing in a split
The optimum specimen aspect ratio for compressive and Hopkinson (Kolsky) Pressure Bar (SHPB) system. Con-
combined compressive and shear strain loading was ventional Hopkinson bar systems with metallic rods, are not
determined by Finite Element Analysis using previously suitable for testing compliant materials such as foam. The
published properties of a different batch of the same high impedance mismatch results in high noise-to-signal
material [2] (Fig. 5). Since this analysis was of a qualitative ratios and short duration pulses that do not reach high
nature, it was not absolutely necessary to use the exact enough strain levels over a more extended period of time
same properties of the as yet uncharacterized material. The necessary to obtain a complete stress-strain curve of the
higher the aspect ratio the more homogeneous is the state of material. To overcome these problems, polymeric rods have
strain. An aspect ratio of 10 was deemed suitable for been proposed and used by several investigators [15, 18,
compression experiments. For the loading configurations of 20, 24–26]. A SHPB system was built of polymeric
Fig. 4 the stresses are (polycarbonate) rods (Fig. 8). The polycarbonate material
P cos q P sin q has an impedance that is closer to that of foam than metals
s3 ¼ and t 13 ¼ ð1Þ as shown in Table 1 below. The polycarbonate material
A A
selected exhibits a low degree of viscoelastic behavior and
and the engineering strains are consequent dispersion and attenuation of the stress waves
d compared to other polymeric materials used in SHPB
"3 ¼ cos q ; "1 ¼ "2 ¼ 0
t systems. The viscoelastic wave propagation in the polycar-
d sin q "3 tan q ð2Þ bonate rods was analyzed by FFT and the frequency
g 13 ¼ tan1 ¼ tan1 g ¼ g 23 ¼ 0;
t  d cos q 1  "3 12 dependence of the attenuation and phase velocity in the
rods was determined. It was found and verified experimen-
tally that the phase velocity remains nearly constant for the
where P is the applied load, A the area of the foam plate
relevant frequencies of the loading pulse applied and that
specimen, d the applied vertical displacement, and t the
the loading pulse exhibited negligible attenuation and
specimen thickness.
dispersion during its propagation along the polycarbonate
Shear stress tests can be conducted under stress or strain
rod (Fig. 9) [15]. The experimental setup for uniaxial
control to yield shear moduli since there is no interaction
compressive strain tests in the SHPB system is shown in
between shear stresses and normal strains for small to
Fig. 10. The disk-like specimen is 6 mm thick and
moderate deformations (Fig. 6). The optimum aspect ratio
sandwiched between and bonded to metallic shims
for shear specimens was also determined by Finite Element
(0.1 mm thick) which constrained deformation in the radial
Analysis as shown in Fig. 7.
direction. Thus, the specimen was subjected to uniaxial
For the shear test configuration shown in Fig. 6, the
compressive strain only. It was determined that stress
stresses are
equilibrium is reached after approximately 12 traverses of
P the stress wave through the specimen. This occurs in less
t 13 ¼ and s 3 ¼ 0 ð3Þ
2A than 70 μs, which is a very short portion of the pulse

Table 1 Impedances of
Hopkinson bar and foam Material E, MPa ρ,kg/m3 Z(=ρc), kg/m2s
materials
Steel 207,000 7,800 4.0×107
Aluminum 73,000 2,800 1.4×107
Polycarbonate 2,410 1,200 1.7×106
PVC Foam (DIAB H250) 322 (through-thickness) 250 2.8×105
PVC Foam (DIAB H250) 207 (in-plane) 250 2.3×105
Exp Mech (2011) 51:1395–1403 1399

Fig. 9 Incident and transmitted Incident wave


stress wave pulses in SHPB
0.4
apparatus made of polycarbon-
ate rods without a specimen 0.2

0
0.0002 0.0004 0.0006 0.0008 0.001 0.0012 0.0014 0.0016
-0.2
Time, (s)
-0.4
-0.6

-0.8
Transmitted
-1 wave
-1.2

-1.4

duration (Fig. 9). (A detailed analysis of dynamic testing of direction (1- or 2 -direction). The effect of anisotropy is
foams in the SHPB system with more extensive results and reflected in the variation in axial modulus and character-
discussion will appear in a forthcoming paper). istic first peak in the stress-strain curve. The latter, as
mentioned before, is the “critical point” of initiation of
local collapse of the cell structure. The variation of the
Engineering Properties axial modulus with load orientation is not monotonic and
shows a local minimum although the elastic constants
Typical stress-strain curves along principal material direc- along the principal material axes satisfy the following
tions for the material studied, obtained under uniaxial stress inequality (Fig. 14) [27].
loading, are shown in Fig. 11. It is seen that the material
E3
behavior is noticeably anisotropic and different in tension G13 >    84 MPa ð5Þ
E
2 E1 þ n 31
3
and compression. The compressive behavior of the foam is
of interest in most applications. A typical compressive
stress-strain curve with its characteristic features is shown Figure 15 shows the variation of the “critical stress” with
in Fig. 12. The linear elastic behavior is associated with loading orientation. The trend is similar to that of the initial
bending or stretching of the cell walls; yielding is caused by modulus shown in Fig. 14 with a local minimum occurring
the formation of plastic hinges at the edges of the cells; the at around 20°. Shear stress-strain curves, obtained from the
local peak or “critical point” is related to initiation of cell test configuration of Fig. 6, are shown in Fig. 16. The
collapse; the plateau region is caused by continuing cell above tests yielded the quasi-static engineering constants,
collapse and plastic deformation; the final densification E1 = E2 , E3 , ν12, ν13 = ν23 , G12, G13 = G23 of the material
stage corresponds to complete collapse and touching of cell shown in Table 2.
walls. Typical ultimate compressive strains are on the order
of 70%.
Compressive stress-strain curves for the off-axis
specimens tested under uniaxial stress are shown in
Fig. 13 at various orientation with respect to the in-plane

Polycarbonate bar specimen

Fig. 10 High strain rate testing in SHPB under uniform normal Fig. 11 Typical stress-strain curves of Divinycell H250 foam loaded
compressive strain along principal directions [2]
1400 Exp Mech (2011) 51:1395–1403

400

350

300

Ex, MPa
250

200

150

100
0 20 40 60 80 100
Off-axis Angle, Degree

Fig. 14 Variation of axial modulus with load orientation from the 1-2
plane

conditions were obtained at three strain rates and are shown in


Fig. 18. These tests yielded the stiffness components C11 =
C22 and C33 shown in Table 3.

Poisson’s Ratio
Fig. 12 Typical stress-strain curve and characteristic features of a
foam under uniaxial compression The uniaxial strain experiments did not yield the Poisson’s
ratios directly. These were calculated by the known
Stiffness Properties interrelations between the engineering and mathematical
stiffness constants. The mathematical constants C11 = C22
Compressive stress-strain curves along the in-plane and and C33 are related to the engineering constants as follows:
through-thickness directions under uniaxial strain are  
E1 E1  v213 E3
shown in Fig. 17. All strain components other than the C11 ¼   ð6Þ
one measured are constrained to be zero. High strain rate E1 ð1  v12 Þ  2v213 E3 ð1 þ v12 Þ
tests up to 103 s−1 were also conducted under nearly
homogeneous uniaxial strain by using thin disk-like speci-
mens in the SHPB system. Stress-strain curves under these E1 E3 ð1  v12 Þ
C33 ¼   ð7Þ
E1 ð1  v12 Þ  2v213 E3
6 90°
75° 6.5
45°
5
0° 6.0
20
4
Max. Stress, MPa

5.5
Stress, MPa

3
5.0

2 4.5

1 4.0

0 3.5
0 0.05 0.1 0.15 0.2 0 20 40 60 80 100
Strain Off-axis Angle, Degree

Fig. 13 Compressive stress-strain curves of off-axis specimens for Fig. 15 Variation of “critical stress” of cell structure with load
loading orientations of 0, 20, 45, 70, and 90 deg with the 1-2 plane orientation from the 1-2 plane
Exp Mech (2011) 51:1395–1403 1401

Fig. 16 Shear stress-strain


d
curves on the 1-2 and 1-3 planes ε i ≅ 0 γ 13 = γ 5 ≠ 0 γ 13 =
t
1 d • Strain rate at ~ 5 x 10(-4)/s
t (thickness)
6
τ 13 − γ 13
5

Stress, MPa
3 4
τ 12 − γ 12
3

extensometer 0
0.0 0.2 0.4 0.6
Strain

From the above, we can obtain the Poisson’s ratios as


follows:

  rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
     ffi
2
 E1 C33
E3 C11 1 E3
C33 þ E1 C33
E3 C11 1  CE333  8 EE13 C33
C11 1 þ CE333 þ 16
v12 ¼ ð8Þ
4

sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 ffi where E is the Young’s modulus of the foam, ρ the density, C1
E1 ð1  v12 Þ E3 and C2 are constants, and ϕ is material fraction in the edges of
v13 ¼ 1 ð9Þ
2E3 C33 the cell usually varying between 0.6 and 0.8. Consequently,
(1-ϕ) represents the material fraction in the faces of the cell.
Results from the calculations above are included in
The subscript b denotes bulk material property. The gas
Table 3. The difference noted in the quasi-static Poisson’s
pressure inside the cell is neglected for the small strains
ratio v12 (in Tables 2 and 3) can be attributed to the
considered in determining the Young’s modulus.
different test conditions, measurement techniques and
The relation above can be simplified into the form
deformation localization in the material.
 2  
E r r
¼C þ ð1  CÞ ð11Þ
Eb rb rb
Modeling of Young’s Modulus
which involves only one constant and satisfies the limiting
As mentioned before, several models have been proposed condition
for estimation of the Young’s modulus of the foam in terms
of its density and properties of the bulk material [3–5, 12]. E ¼ Eb when r ¼ rb ð12Þ
Gibson and Ashby assumed a cubic array of cells and by
analyzing the bending and stretching of the cell walls The modulus in the though-thickness direction obtained
proposed the following semi-empirical relation for a closed- in the present characterization and similar values published
cell foam [3] by the manufacturer [28] for the Divinycell H series were
 2   fitted to the relation (11) and plotted versus relative density
E r r r=rb in Fig. 19. The values of Eb = 1,650 MPa and
¼ C1 ϕ þ C2 ð1  ϕÞ ð10Þ
Eb rb rb rb ¼ 1; 030 kg/m3 for the bulk PVC were obtained from

Table 2 Quasi-static engineer-


ing properties of divinycell H250 E1 = E2 MPa E3 MPa ν12 ν13 = ν23 G12 MPa G13 = G23 MPa

201 322 0.33 0.20 85 110


1402 Exp Mech (2011) 51:1395–1403

Fig. 17 Stress-strain curves


under uniaxial compressive
εi ≅ 0 ε3 ε3 0
strain • Strain rate at ~ 5 x 10(-4)/s
14

12
3
10
σ3 −ε3

Stress, MPa
8
1 6
σ 1 − ε1
4
extensometer 2

0
0.0 0.2 0.4 0.6 0.8 1.0
Strain
ε3

16

14 ~ 103/s

12

10
Stress, MPa

~ 100/s
8

6 ~ 10-4/s

0 Fig. 19 Variation of through-thickness modulus of Divinycell H


0.0 0.2 0.4 0.6 0.8 1.0 foams with density-comparison of model predictions and experimental
Strain results

Fig. 18 Stress-strain curves in the in-plane (1 or 2) direction obtained


under uniaxial compressive strain at three strain rates

Table 3 Mechanical properties


of divinycell H250 at different strain rates

Property Average Strain Rate, s−1

10−4 1 103

Poisson’s Ratio, v12 0.29 0.26 0.26


Poisson’s Ratio, v13 = v23 0.20 0.19 0.19
In-plane Shear Modulus, G12, MPa 85 87 –
Through-thickness Shear 110 111 –
Modulus G13 = G23, MPa
Stiffness, C11 = C22, MPa 250 247 254
Stiffness, C33, MPa 388 378 399
Peak stress (in-plane), MPa 5.0 7.5 9.0 Fig. 20 Prediction of simplified model and experimental results for
through-thickness modulus of Divinycell H foams
Exp Mech (2011) 51:1395–1403 1403

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