Impact dynamics of metal foam shells for motorcycle helmets: Experiments & numerical modeling

To reduce the weight of motorcycle helmet, metal foam for outer shell in place of conventional thermoplastics was tested. The dynamic behaviour of this new helmet was studied through experiments and numerical modeling. Open-face motorcycle helmets were designed with metal foam shell and impact experiments were performed with these helmets fitted on a headform. A finite element model was developed and the predicted acceleration of headform from this model was validated against the experiments. The mechanical behaviour of full-face helmets with metal foam shell was investigated next. The FE analysis was performed separately with rigid and deformable heads. Head injury criterion (with rigid head) and stresses in brain (with deformable head) were evaluated separately for metal foam shell and ABS shell helmets. The helmet impact performance is examined with two separate densities of metal foam. The shell with low-density metal foam (150 kg/m3) gives a better performance compared to ABS shell. The metal foam shell showed significant visible plastic deformation in the impact region.