Numerical modeling and topological analysis of entangled single-wire metal rubber

Metal rubber materials, formed by entangling single metal wires and also known as ESW-MR, have attracted widespread attention due to their unique non-linear load curves and excellent environmental adaptability. The mechanical behavior of these materials, which are created through the weaving or winding of pure metal wires, is influenced by the structural characteristics of semi-flexible fiber cross-linked fibers. This study delves deeply into the microstructure of ESW-MR, with the aim of establishing a numerical model that can accurately simulate and characterize its structure. A method based on arbitrarily defined baselines parametric equations in the global space was adopted, leading to the creation of a parametric model for a continuously wound wire with multiple spiral mechanisms. Finite element simulations based on explicit dynamics were conducted using LS-DYNA and could successfully simulate the cold stamping forming process of ESW-MR blanks. The model was validated through stamping and quasi-static tests, as well as computed tomography (CT) scan tests. The results demonstrate the model accuracy in describing the macroscopic and microscopic characteristics of the material, showing excellent agreement with the actual material. Furthermore, the study successfully extracted the microtopological features of the material, providing additional quantitative information on the topological characteristics of ESW-MR. This work offers a valuable tool for the study and application of ESW-MR and presents a novel perspective for the numerical simulation of a wide range of entangled materials. It paves the way for gaining a deeper understanding of the microstructure and mechanical behavior of such materials.