Large Deformation Finite Element Analyses for 3D X-ray CT Scanned Microscopic Structures of Polyurethane Foams

Polyurethane foams have unique properties that make them suitable for a wide range of applications, including cushioning and seat pads. The foam mechanical properties largely depend on both the parent material and foam cell microstructure. Uniaxial loading experiments, X-ray tomography and finite element analysis can be used to investigate the relationship between the macroscopic mechanical properties and microscopic foam structure. Polyurethane foam specimens were scanned using X-ray computed tomography. The scanned geometries were converted to three-dimensional (3D) CAD models using open source, and commercially available CAD software tools. The models were meshed and used to simulate the compression tests using the implicit finite element method. The calculated uniaxial compression tests were in good agreement with experimental results for strains up to 30%. The presented method would be effective in investigating the effect of polymer foam geometrical features in macroscopic mechanical properties, and guide manufacturing methods for specific applications.