Simulative Determination of Effective Mechanical Properties for Digitally Generated Foam Geometries

Metal foams constitute a promising and emerging material class in the context of lightweight construction. There exists a variety of different foam topologies, on which resulting mechanical properties depend. To maximize the potential of foams in material use under mechanical load, the present work addresses the question how different geometrical parameters influence the material behaviour. Therefore, an algorithm for digital generation and design of open pore foam structures is presented, that allows to regulate the geometry precisely. A method for retrieving effective mechanical properties from numerical simulations of compression tests in the elastic regime is introduced. Additionally, the representativeness of foam volumes considered for simulations is investigated. This yields a fully digital workflow, which enables the investigation of geometry influence on mechanical properties. This approach is used to conduct simulation studies on generated foam structures with a systematic variation of geometrical parameters. Herein, a range of effective Young's moduli varying by up to a factor of 1.3 for different foam structures at the same porosity is found. This shows a significant impact of the foam geometry on the elastic properties of metal foams. The presented methodology yields insights, which can guide design and optimization of materials for specific applications.