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Failure characteristics of strength-equivalent aluminium and steel plates in


impact conditions

Conference Paper · March 2013


DOI: 10.1201/b15120-25

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Failure characteristics of strength-equivalent aluminium and steel plates


in impact conditions

B. Liu, R. Villavicencio & C. Guedes Soares


Centre for Marine Technology and Engineering (CENTEC), Instituto Superior Técnico,
Technical University of Lisbon, Portugal

ABSTRACT: Experimental drop weight impact tests have been performed to examine the failure
characteristics of small-scale clamped rectangular plates stuck laterally by a mass with a spherical indenter.
The experiments are conducted on aluminium and steel plates of the same bending stiffness. Thus, the
impact tests describe the behaviour of strength-equivalent ship building materials subjected to rapidly
varying loads. The experimental results are presented in terms of the force-displacement responses and
the failure modes of the specimen plates, which are very sensitive to the diameter of the indenters. Also,
the experimental results show that the critical deflection is similar for both the aluminium and steel plates
while some differences are observed in the critical force and energy. In addition, the magnitudes of the
critical deflection, force and energy are compared a static theoretical prediction to allow the selection of
equivalent impact strength plates.

1 INTRODUCTION Table 1. Comparison of aluminium and steel plates.

The aluminium can replace the steel in the Aluminium: Lightweight; expensive; no corrosion; low
construction of the hull structures in order to yield stress; low ultimate tensile stress; low fracture
strain; may melt in fire.
reduce the total weight of the ship, particularly for
high-speed ships. Design criteria can convert the
Steel: Heavy; cheap; corrosion; simple to fabricate.
steel to the strength-equivalent aluminium struc-
ture by the same deflection and stiffness (Lamb Thickness (t) tal = 1.42 tst
and Beavers 2010; Kasten 2010). Nevertheless, Young’s modulus (E) Eal = 0.35 Est
ships suffer rapidly varying loads, such as slam- Bending stiffness (Et3) Eal tal3 = Est tst3
ming, ice-impact and collision and grounding. In Deflection (w) wal = wst
the bottom and bow flare slamming, the shell plat- Density (ρ) ρal = 0.34 ρst
ing and its supporting structure are subjected to Weight (m) mal = 0.48 mst
high impact pressure forces, which accelerate and
deflect all of this structure and set up vibrations, *Subscript al and st represents aluminium and steel,
particularly in the plating. During ship collisions respectively.
and groundings, the ship structure should be capa-
ble to absorb the impact energy without undergo- achieve the same steel stiffness due to the smaller
ing certain types of failure. Young’s modulus.
Since the aluminium and the steel behave as Experimental tests of laterally loaded rectan-
brittle and ductile material, respectively, their gular plates have been conducted to derive ana-
impact strength should be compared to guarantee lytical expressions of the plastic response and
the safety of the design. Some advantages and dis- failure of aluminium and steel plates. For exam-
advantages of aluminium and steel plates with the ple, Jones (1971) proposed an energy approach,
same stiffness are listed in Table 1. The coefficients based on the rigid-plastic theory, to estimate the
used to replace the steel plates by aluminium are permanent deflection of rectangular plates under
also indicated in Table 1. Usually, the steel expe- uniformly distributed loads. Zhu et al. (1994)
riences larger yield stress, ultimate tensile stress used the energy approach of Jones to study the
and fracture strain. Also, the material strain rate dynamic behaviour of plates subjected to low
sensitivity is more evident for the steel, improving velocity impacts.
its structural crashworthiness. The thickness of the The initiation of rupture is an important
replaced aluminium structure should be larger to aspect in the analysis of laterally impacted plates.

167
Therefore, Shen et al. (2002a, b) proposed a is used to determine the engineering stress-strain
theoretical method to predict the onset of failure behaviour of the material. The mechanical proper-
for thin circular plates stuck by a conical indenter, ties of the aluminium and steel materials are sum-
and Simonsen and Lauridsen (2000) and Lee et al. marized Table 2 and the engineering stress-strain
(2004) developed analytical formulae to estimate curves are shown in Figure 2. The steel has bet-
the deformation and failure of thin clamped plates ter elastic properties since the yield stress is larger
punched by a spherical indenter. Moreover, it has than that of the aluminium (∼82%). Also, the steel
been demonstrated that the plastic deformation withstands larger stresses before necking because
until failure is strongly dependent on the shape of of its larger ultimate tensile strength (∼42%). The
the indenter as summarised by Jones et al. (2008, aluminium fractures at the maximum load while
2012) when proposed a theoretical method to pre- the steel necks decreasing the level of stresses until
dict the dimensionless perforation energy for plates fracture occurs.
struck by indenter with different shapes. The plates are fully clamped by four M8 bolts
The present paper investigates the plastic between two thick rectangular steel plates with an
response and failure characteristics of strength- internal cut-out of 127 × 76.2 mm (Fig. 3). The
equivalent aluminium and steel plates. This is bolts compress the specimen and restrict its lon-
done through drop weight impact tests. Different gitudinal displacement between the supports. The
diameters of hemi-spherically ended indenters are support plates are fixed to a strong structural base
used in order to study their influence on the impact to prevent any movement.
response of the specimens. The impact tests pro- The impact tests are performed using a fully
vide the actual force-displacement response and instrumented Rosand IFW5 falling weight machine
failure mode of the plate specimens.
The magnitudes of the critical deflection, force
and energy are compared with the theoretical pre-
dictions proposed by Simonsen and Lauridsen
(2000). The actual experiments and the theoreti-
cal predictions allow the definition of equivalent
impact strength aluminium plates that can absorb
similar incident energy than that of steel plates.
In addition, the specific energy absorption is used
to evaluate the weight effectiveness of the steel
and aluminium plates subjected to lateral impact.
The presented results are of considerable practi-
cal importance to assess the safety of aluminium
and steel structural elements subjected to dynamic
loads, since these calculations require accurate esti-
mates of the large deformations provoked by the
impact. Figure 1. Dimensions of the machined test pieces.

2 EXPERIMENTAL DETAILS
Table 2. Mechanical properties of material.
The experimental program evaluates the plastic Aluminium Steel
response until failure of rectangular plates stuck Property Units 2.0 mm 1.4 mm
laterally by a mass with a spherical indenter. Alu-
minium and steel plates of the same bending stiff- Density kg/m3 2650 7850
ness are selected. The plates are aluminium alloy Young’s modulus GPa 72 206
5083/H111 (2.0 mm thickness) and mild steel ST12 Poisson’s ratio - 0.33 0.3
(1.4 mm thickness). The mechanical properties are Yield stress MPa 125 228
obtained by quasi-static tensile tests carried out on Ultimate tensile MPa 257 364
material cut from the same plates from which the strength
impact specimens are taken. The dimensions of the Fracture stress MPa 257 272
machined tensile test pieces are shown in Figure 1. Fracture strain - 0.15 0.23
Three tensile tests are conducted for each mate- (100 mm)
rial at a rate of 1.0 mm/min until fracture occurs. Strength MPa 405 585
coefficient C0
The displacement-controlled tension tests are car-
Strain hardening - 0.160 0.172
ried out with a tensile test machine INSTRON exponent n
3369. It records the force-elongation curve, which

168
Figure 2. Engineering stress-strain curves of aluminium
and steel material.

Figure 4. Fully instrumented Rosand IFW5 falling


weight machine.

absorbed energy and the velocity are calculated


from the measured force-time data by successive
numerical integrations. Four hemispherically ended
strikers of diameters 30, 20, 16 and 10 mm are
evaluated. The incident kinetic energy is 250 J for
the aluminium plates and 400 J for the steel plates.
The impact response of the aluminium and steel
plate is compared at the critical incident energy,
i.e. when failure occurs. Therefore, the incident
energy could be overestimated for some specimens.
However, the tendencies of the force-displacement
curves are not affected with this overestimation.
The last statement is valid as far as the material
strain rate sensitivity is negligible.

3 EXPERIMENTAL RESULTS
Figure 3. Experimental set up.
In all cases, the specimens suffer large plastic defor-
mation and fail at the impact point. The magni-
(Fig. 4). A small, light, hemispherically ended tudes of the critical forces, deflections and absorbed
indenter is dropped from a known, variable height energies at failure are summarized in Table 3. These
between guide rails onto horizontally supported magnitudes are measured at the peak force, which
specimens. A much larger mass is attached to the occurs at the initial rupture of the plates. The
indenter and a load cell between the two gives the critical energy is smaller than the incident kinetic
variation of the impact force with time. An optical energy. The diameter of the indenter strongly
gate provides the incident velocity of the impact influences the experimental results, particularly the
head. The time histories of the displacement, the specimens impacted with larger indenters absorb

169
Table 3. Summary of experimental results.

Values at failure
Input
energy Force Defln Energy
Specimen* (J) (kN) (mm) (J)

AL-D30 250 23.8 18.7 199.2


AL-D20 250 17.9 18.1 149.5
AL-D16 250 15.4 16.9 125.4
AL-D10 250 9.7 13.1 61.9
ST-D30 400 27.5 18.7 257.1
ST-D20 400 21.8 17.8 209.6
ST-D16 400 18.9 16.0 149.4
ST-D10 400 11.8 12.9 76.9 Figure 5. Shape of the deformation. (a): AL-D30;
(b): ST-D30; (c): AL-D20; (d): ST-D20; (e): AL-D16;
*Specimen Notation. AL and ST: aluminium and steel, (f): ST-D16.
respectively; D30, D20, D16 and D10: diameter of
indenter 30, 20, 16 and 10 mm, respectively.

more energy and, consequently, larger forces and


deflections develop. The aluminium plates absorb
less energy than the steel plates (22%). Also, the
critical force of the aluminium plates is about 17%
smaller than for the steel plates. However, both alu-
minium and steel plates suffer similar deflection at
failure (2.2%).
Since the strength-equivalent aluminium plates
present unfavourable energy absorbing capabili-
ties, it is not appropriate to replace steel plates in
the design of structures subjected to lateral impact.
Therefore, the thickness of the aluminium plates
should increase to improve the impact strength
characteristics. This is possible since the weight of
the aluminium is smaller than the one of the steel
(Table 1).
The shape of the deformation of the aluminium Figure 6. Deformation profile of the rectangular
and steel plates is shown in Figure 5. The plates plates.
struck by the indenter with diameter 10 mm are not
included in Figure 5, since the final perforation is
affected by the geometry of this striker. Large plas- configuration. This stretching rises into an axial
tic deformation develops in the specimens in order membrane strain and associated membrane force.
to absorb the external dynamic energy. The defor- Thus, the plate deforms plastically due to the mem-
mation of the specimens is divided into two parts, brane forces at the necking circle. When the speci-
global deflection and local indentation (Shen et al. mens suffer considerable plastic strain, the crack
2002a; Liu et al. 2012), as indicated in Figure 6. is initiated at the necking circle in the direction of
The local indentation has the shape of the striker the short span (Fig. 6) since the membrane force
head. The large external dynamic energy produces is much larger in this direction. In this paper the
structural in-plane tearing failure due to the exces- characteristic failure mode is named ‘tensile fail-
sive in-plane tensile strain (Shen et al. 2002a). The ure’ since the necking circle experiences tensile
spherical indenter penetrates the plate with ductile stretching, after severe indentation, and thinning
enlargement to elongate the material in a plastic in the thickness direction. Finally, the fracture is
flow field below the indenter, forming a circular propagated through the necking circle while the
edge named necking circle, as shown in Figure 6. indenter pushes the plate.
In general, the diameter of the necking circle is The failure mode of the specimen plates is similar
smaller than the one of the striker. As the supports to the mode observed in plate quasi-static punch-
of the laterally impacted plate are restrained axially, ing tests (Lee et al. 2004, Ehlers 2010, Atkins et al.
the centre line of the plate is longer in the deformed 1998) and dynamic impact tests (Shen et al. 2002a).

170
Figure 7. Force-displacement responses. Different diameters of indenters. (a): aluminium plate; (b): steel plate.

It must be mentioned that the energy absorbing to resist the impact load. It is also a measure of the
mechanisms are similar between dynamic and resistance of the specimen to plastic deformation
static tests of ship structures with the same struc- until failure. The reduction of the slope is due to
tural arrangement. However, the energy absorbed more localised contact surface between the striker
in dynamic tests could be larger than that absorbed and the specimen. This smaller contact effect mini-
in the corresponding static tests, a circumstance mizes the instantaneous reaction force for a partic-
attributed to the phenomenon of material strain- ular deflection. Furthermore, the absorbed energy
rate sensitivity (Jones and Wierzbicki 1983). decreases because the specimens impacted by
The aluminium and steel plates show similar smaller indenters experience smaller local indenta-
global deflection and local indentation since they tion and, consequently, form a smaller necking cir-
suffer close deflection at failure. The equivalent cle. This provokes easier rupture of the specimens.
strain distribution near the impact point can influ- It should be mentioned that the slope of the steel
ence the deformation mode of the specimens. In plates is larger than the one of the aluminium plates
particular, this strain distribution is strongly influ- since the steel plates have larger impact resistance
enced by the coefficient of friction between the before failure.
interfaces of the indenter and the specimen (Lee
et al. 2004). If this coefficient is zero the plate rup-
ture at the centre, while if this coefficient grows 4 ANALYTICAL APPROXIMATION
the diameter of the necking circle may increase,
as numerical simulations demonstrated. Since Analytical approaches have been proposed to pre-
the static friction between aluminium-steel and dict the deformation and failure of plates under a
steel-steel are similar (Villavicencio et al. 2012, quasi-static spherical punch loading. In the present
Liu et al. 2012, Lee et al. 2004), the necking circle paper, the theoretical approach of Simonsen and
for both types of specimens follow the same pat- Lauridsen (2000) is selected to analyse the failure
tern at the local indentation. In the actual experi- characteristics of the current aluminium and steel
ments, the final shape of the deformation of the plates. The comparison with quasi-static formulae
aluminium plates, compared with the steel plates, is valid since the incident impact velocity at failure
exhibits some small cracks which initiate in the is relatively low.
necking circle and extend towards the indentation. Simonsen and Lauridsen (2000) investigated the
This occurs because the aluminium has less plastic onset of failure for static lateral punch indentation
deformation capabilities as observed in the engi- of a rigid sphere into a thin clamped circular plate.
neering stress-strain curve (Fig. 2). The analytical approach predicts the plate failure
The impact behaviour of the specimens and the energy absorption up to this point. It was
during the impact event is better described by demonstrated that the response of the thin plates
the recorded force-displacement data (Fig. 7). depends on the strength coefficient C0 and the
The critical absorbed energy is the integration strain hardening exponent n of the material.
of the force-displacement curve until the peak force. The strength coefficient and the strain harden-
The diameter of the indenter strongly influences the ing exponent define the true stress (σt) and true
impact response of the plates since it changes the strain (εt) material curve based on the simple power
dimension of the local indentation. law relation. This curve gives an approximate true
The slope of the force-displacement curves indication of the deformation characteristics of a
decreases for specimens impacted with smaller metal (Dieter 1986):
diameter of indenter. This slope is the instantane-
ous stiffness of the specimen, indicating its ability σt C εt n (1)

171
The parameters of the power law relation are and steel material the hardening exponent is very
determined from the engineering stress-strain similar, 0.160 and 0.172, respectively. Therefore,
curve. The exponent n is the linear slope of a log- Equation (2) estimates similar deflections for the
log plot of the logarithmic true stress and true aluminium and steel plates when impacted by the
strain up to the maximum load expressed in terms same type of indenter (difference 2.4%). This is
of the engineering stress and engineering strain. demonstrated in the experimental results (Table 3).
The coefficient C0 is the true stress at εt = 1.0. In Equation (2), the relationship between the
The tensile tests of aluminium plates show that deflection and the diameter of indenter is δf ∼ Rb0.52.
the stress at maximum load is almost coincident This implies that the deflection at failure decrease
with the fracture stress and that very little necking accelerated with the diameter of indenter, as also
occurred in the width direction. However, necking observed in the current impact tests.
is observed in the thickness direction. For that rea- The theoretical approach of Simonsen and Lau-
son, the true material relation for the aluminium ridsen (2000) was followed by Lee et al. (2004) to
plates is also defined beyond the maximum load evaluate the influence of the material ductility. Lee
(Børvik et al. 2009; Beese et al. 2010). Here, the et al. (2004) demonstrated that the strain harden-
parameters C0 and n are obtained using the set of ing exponent can be replaced by the critical dam-
equations proposed by Zhang et al. (2004). The age value for ductile fracture:
coefficients of the power law relation for both
aluminium and steel materials are summarised in δf
Table 2. = 2 Dc ξ00.38 (3)
R0
Simonsen and Lauridsen (2000) estimated the
normalized penetration until failure for circular
plates by: where Dc is the critical damage value for ductile
fracture. This equation is valid for 0.1 < ξ0 < 0.75.
The critical damage value is a function of the criti-
δf
= 1.41n0.33ξ00.52 (2) cal failure strain obtained from the tensile test sim-
R0 ulations. Since the accuracy of these simulations is
relatively low beyond localisation, the failure strain
where δf is the critical punch penetration to failure, is only approximated, and thus this new approach
R0 is the radius of the clamped plate, n is the strain is less accurate. In addition, Equation (3) is not
hardening exponent and ξ0 = Rb/R0 is the dimen- appropriate to estimate the deflection of the plate
sionless radius of the applied punch where Rb is for larger failure strains, because the deflection at
the radius of the spherical punch. This equation is failure is determined by the failure at the necking
valid as far as 0.1 < ξ0 < 0.5 and 0.1 < n < 0.3. The circle (Fig. 6). For example, the deflection at fail-
deflection of these thin plates is independent of the ure is similar for a range of plastic strains between
plate thickness and the yield stress since the bend- 0.7 and 1.2, which are obtained from numerical
ing resistance can be neglected. Thus, the plate simulation of tensile and impact tests (Liu et al.
response is governed by the membrane force. This 2012). However, Equation (3) is very sensitive to
phenomenon is manifested in tensile test results of the critical damage coefficient, thus it is appropri-
specimens manufactured with the same material ate for low failure strains, as the ones obtained in
but different thickness since they should result in the actual aluminium plates.
the same engineering elongation. Also, materials The reaction force until failure for the circular
with different yield stress but similar strain hard- plates of Simonsen and Lauridsen (2000) can be
ening exponent could result in similar elongation expressed as:
until fracture. This is due to the fact that the strain
hardening exponent determines the elongation at 2π C0t0 Rb [ − l ψ c ]n cos
cosψ c i 2 ψ c (4)
fracture of the material.
The penetration until failure for circular plates where C0 is the strength coefficient, t0 is the plate
is similar to the penetration for square plates where thickness and ψc is the critical wrapping angle to
the initial half-width corresponds to the initial failure:
radius R0 (Lee et al. 2004). Therefore, the theo-
retical model of Simonsen and Lauridsen (2000) is c ≈ 0.957 + 0.399 n (5)
used to evaluate the parameters that influence the
deformation process of the actual plates. The absorbed energy until failure is:
Equation (2) shows that the strain hardening
exponent determines the deflection at failure of
geometrically similar specimens manufactured E π C0t0R0Rb { ξ00.607 − 0.387ξ0 + ξ02

with different materials. In the actual aluminium + 0.067( n − 0.2 )} (6)

172
Equations (4) to (6) are valid within the range The critical energy, for a given plate geometry
0.1 < ξ0 < 0.5 and 0.1 < n < 0.3. It should be noticed (width × length) and material, is proportional
that the reaction force (Equation 4) is independ- to the plate thickness (Equation 6). Thus, the
ent of the radius of the plates. Simonsen and Lau- absorbing capability of this particular plate can
ridsen (2000) demonstrated the reaction force is be improved by increasing its thickness. In the
similar for plates with circular, square and rectan- actual experiments, the aluminium plates require
gular geometries, i.e. the influence of the specimen to absorb 1.3 times more energy to make equal the
geometry is negligible to estimate this force. This is energy absorbed by the steel plates. This implies
possible since the specimens suffer the local inden- that the thickness of the aluminium plates should
tation far away from their boundaries (Simonsen be increased to 2.6 mm. It can be concluded that
and Lauridsen 2000). Thereby, Equation (4) is the impact tests can estimate the thickness neces-
adopted to analyse the current rectangular plates. sary to absorb the same energy absorbed by the
Equation (4) predicts similar reaction forces for parent plate. Therefore, the relation tal = 1.42tst
the aluminium and the steel plates; the difference is ∼ for strength-equivalent aluminium and steel plates
1.1%. However, the experimental results demonstrate should increase to tal = 1.85tst in order to satisfy the
that the peak force for the steel plates is ∼17% larger same impact strength. This linear relation is valid
than that for the aluminium plates (Table 3). Since for thin plates and assumes that the critical energy
the theoretical predictions are similar to the experi- varies proportional to the plate thickness. The
mental results of the aluminium plates, the differ- latter is based on quasi-static punching tests and
ence in the experimental reaction forces is attributed could be used to estimate the impact strength of
to small strain rate effects of the mild steel plates aluminium plates since the aluminium is essentially
when subjected to dynamic impact loads. It must be strain rate insensitive.
mentioned that the quasi-static approach should be The absorbed energy is often divided by the
similar to the dynamic experimental response of the weight of the structure to give the specific energy
aluminium plates because the aluminium alloy mate- absorption (Se) which is widely used to judge the
rial is essentially strain rate insensitive (Jones 1989). relative effectiveness of various energy absorb-
The absorbed energy until failure is the numeri- ing devices and structures (Jones and Wierzbicki
cal integration of force-displacement relationship. 1983). The materials with high Se offer the potential
Therefore, the theoretical energy (Equation 6) for significant weight reduction in energy absorb-
includes the parameters used to estimate both ing components, usually used in the design of cars,
the deflection and reaction force. As the analyti- airplanes, ships, etc. In the present work, the same
cal deflections and reaction forces until failure are principle is used to evaluate the absorbing capabil-
very similar for the aluminium and steel plates, the ity of the steel and aluminium plates.
theoretical critical energies predict also close mag- The aluminium has higher Se due to its smaller
nitudes. This similitude differs from the experi- density, offering potential for significant weight
mental results as shown in Table 3. The difference reduction in energy absorbing components. More-
between the experimental forces is responsible for over, the larger thickness for the aluminium plates
this difference in the energy absorption. (tal = 1.85tst) reduces the deflection compared with
the steel plates, improving the designed structural
yield and buckling strength.
5 DISCUSSION In the actual experiments, the Se of the aluminium
is larger than the one of the steel (about 63%). Thus,
The present paper investigates the impact charac- the steel plate weighs 63% more than the aluminium
teristics of strength-equivalent aluminium and steel plate if both have the same energy absorption until
plates for application in ship structural design. For failure. This implies that the aluminium material is
converting a parent steel ship, that satisfies rule advantageous respect to the weight effectiveness to
requirements in terms of structural strength, to an resist lateral impact. The Se estimates the reduced
equivalent aluminium ship, three design param- weight with the same energy absorption until fail-
eters should be considered: stress, deflection and ure for the preliminary design. Thus, the carrying
weight. The equivalent ship manufactured in alu- capacity, stability and cruising speed based on the
minium should have an equal or better structural steel parent ship can be evaluated.
integrity than the parent steel ship.
The coefficients used to replace the steel plates
by aluminium plates (Table 1) are valid within the 6 CONCLUSIONS
elastic limit, so they use a safety factor smaller than
the yield stress. However, the design of structures The failure of the laterally impacted aluminium
subjected to dynamic impact requires the inclusion and steel plates is analysed through drop weight
of the nonlinear behaviour of the material. impact tests and theoretical analyses. This provides

173
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ium plates. for finite element simulations of a thin circular plate.
Thin-Walled Structures; 48: 1–8.
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plates experience similar deflections until failure plastic behaviour of beams and plates with finite-
although the forces and the energy are larger in the deflections. International Journal of Solids Structures;
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perforation of mild steel rectangular plates with pro-
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necking circle due to the development of mem- minium alloy plates. International Journal of Impact
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ACKNOWLEDGEMENTS Shen WQ, Rieve NO, Baharun B. 2002a. A study on
the failure of circular plates struck by masses. Part 1:
The work of the first author has been financed by a experimental results. International Journal of Impact
PhD scholarship from ABS, the American Bureau Engineering; 27: 399–412.
of Shipping. The authors are grateful to Dr George Shen WQ. 2002b. A study on the failure of circular plates
Wang for his initiative to promote this scholarship. struck by masses. Part 2: theoretical analysis for the
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neering; 27: 413–432.
Portuguese Foundation for Science and Technol- Simonsen BC, Lauridsen LP. 2000. Energy absorption
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tation by a sphere. International Journal of Impact
Engineering; 24: 1017–1039.
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