Nonlinear finite element analysis of axially crushed cotton fibre composite corrugated tubes

It is proven experimentally that introducing corrugation along a shell generator together with a proper advanced composite material will enhance the crashworthiness performance of energy device units. This is because corrugation along the shell generator will force the initial crushing to occur at a predetermined region along the tube generator. On the other hand, a proper composite material offers vast potential for optimally tailoring a design to meet crashworthiness performance requirements. In this paper, the energy absorption characteristics of cotton fibre/propylene corrugated tubes are numerically studied. Finite element simulation using ABAQUS/Explicit was carried out to examine the effects of parametric modifications on the tube’s energy absorption capability. Results showed that the tube’s energy absorption capability was affected significantly by varying the number of corrugation and aspect ratios. It is found that as the number of corrugations increases, the amount of absorbed energy significantly increases.     

Quasi-static crushing behaviour of hybrid and non-hybrid natural fibre composite solid cones

A comprehensive experimental investigation of the quasi-static axial crushing of hybrid and non-hybrid natural fibre/polyester composite solid cones between flat platens has been carried out. The composite solid cones were fabricated from two types of natural fibres namely oil palm fibre and coir fibre and different vertex angles varied from 0° to 60°. Typical load-deformation histories are presented and discussed. Crashworthiness parameters such as load carrying capacity; energy absorption capability and failure mechanism have been discussed. The results presented in this study will help us to understand the behaviour and characteristics of natural fibre composite as a filler material.     

Effect of fiber orientation on energy absorption characteristics of glass cloth/epoxy composite tubes under axial quasi-static and impact crushing condition

The collapse characteristics and energy absorption capability of composite tubes made of 759/5224 woven glass cloth/epoxy with different fiber orientations were studied in the present article under axial quasi-static and impact crushing condition. The effects of fiber orientation and loading condition on the crushing modes and energy absorption capability were discussed in detail. The fiber orientation could be found to have significant influences on energy absorption performance. Based on results, the energy absorption capability could be improved by selecting proper fiber orientation. The energy absorption capability in impact crushing tests could be found to be slightly lower than that in quasi-static crushing tests.     

Effect of Material and Geometry on Crushing Behaviour of Laminated Conical Composite Shells

This paper examines the effects of the material and structural geometry on the crushing behaviour, energy absorption, failure mechanism and failure mode of circular conical composite shell. The static crushing behaviour of circular conical composite shell under uniform axial compressive load has been investigated experimentally. The cone vertex angles used were 0, 6, 12 and 18 degrees. The cone vertical length and bottom outer diameter were kept for all the cases as 100 and 110 mm, respectively. Failure modes were examined using several photographs taken during the crushing stages for each specimen. Results obtained from this investigation showed that the initial failure was dominated by the interfacial and shear failure, while the delamination and eventually fibre fracture were dominated the failure mechanism after the initial failure. It has also found that the static crushing behaviour of the circular conical shell is very sensitive to the change in the vertex angle. Reinforcement type greatly affects the energy absorption of the circular conical and cylindrical shells.     

A study on crushing behaviors of composite circular tubes with different reinforcing fibers

In this study, the failure modes and energy absorption capabilities of different kinds of circular tubes made of carbon, Kevlar, and carbon-Kevlar hybrid fibers composites with epoxy resin have been evaluated. The relationship between the crushing parameters (specific energy absorption, maximum peak load, mean crushing load) and the material properties for different fibers and patterns was also investigated. The fabric carbon/epoxy tubes had the best energy absorption capability (specific energy absorption of 81.7%). In contrast, the tubes made of Kevlar showed the worst energy absorption capability. Based on the linear regression analysis results, the crushing parameters generally showed good correlation with the compressive strength and shear modulus. In particular, the specific energy absorption of the tubes with the brittle fracture mode revealed the strongest correlation with the compressive strength (R-square value = 0.90).     

Energy absorption and load carrying capability of woven natural silk epoxy–triggered composite tubes

This study investigated the energy absorption response and load carrying capability of woven natural silk/epoxy–triggered composite rectangular tubes subjected to an axial quasi-static crushing test. The rectangular composite tubes were prepared by hand lay-up technique. The tubes consisted of 12, 24, and 30 layers of natural woven silk/epoxy laminate and were 50, 80, and 120 mm long. The crashworthiness of the tubes was evaluated by measuring the specific energy absorption in quasi-static axial compression. Specific energy absorption was obtained from the load–displacement curve during testing. The failure mode of the tubes was analyzed from high resolution photographs obtained. Overall, the tube with 50 mm length and 30 layers showed the best crashworthiness among the tubes. The failure morphology showed that the specimens failed in two distinct modes: local and mid-length buckling. The triggered composite tubes exhibited progressive failure.     

Static and dynamic axial crushing of spot-welded thin-walled composite steel–CFRP square tubes

Thin-walled metallic tubular components have long been adopted in the transportation industries, where the stable energy absorbing crushing process provides protection to occupants and cargo in the event of a collision. Fibre–epoxy tubes provide superior strength to weight ratios, however brittle failure modes may limit their energy absorbing capacity under large axial deformation. Composite steel–CFRP (carbon fibre-reinforced polymer) tubes are a recent advent, and combine the benefits of the stable, ductile plastic collapse mechanism of the steel and the high strength to weight ratio of the fibre/resin composite, to form a composite tube with high energy absorption capability. In this paper the applicability of steel–CFRP tubes to structures typical to the automotive industry is investigated. Thin-walled square tubes with width to thickness ratios up to 120 are cold-formed and spot-welded from high strength, low ductility steel, and subjected to static and dynamic axial compression. Four different steel tube geometries and two different carbon fibre matrix layouts are investigated, and comparisons are made between static and dynamic crushing, steel and composite steel–CFRP tubes, and regular and low ductility steels. It is shown that the crashworthiness properties of the steel–CFRP tubes exceed those of the steel tubes, however some issues particular to low ductility steels and such steels under impact conditions prove detrimental to the crashworthiness characteristics. Theoretical procedures are developed to design the crashworthiness characteristics of the composite tubes, and are shown to compare well with the experimental results.     

玻璃/环氧圆柱管能量吸收细观机理

研究了玻璃纤维增强环氧圆柱管轴向撞击和准静态压缩下的能量吸收特性。总结了稳态压缩的三种宏观破坏模式,即层束弯曲、局部屈曲和横向剪切。从细观角度出发,详细研究了不同宏观破坏模式的复合材料圆柱管的能量耗散机理,并比较了吸能能力。随着铺设角度增大,能量吸收机理由基体控制向纤维与基体共同控制转化,因此能量吸收逐渐增大。本文还比较了撞击和准静态下能量吸收的特点。     

On the energy absorption capability of axially crushed composite elliptical cones

The behaviour of composite elliptical thin walled cones subjected to quasi-static axial crushing is examined experimentally. Series of experiments were performed for composite elliptical cones with the same ellipticity ratio and different vertex angles ranging from 0° to 24°. Experiments showed that the catastrophic failure mode is avoided by deviating from the elliptical tubular shape to the elliptical conical one. A significant enhancement in load carrying capacity and energy absorption capability was seen in the case of elliptical conical shells.     

Energy absorption in composite stiffeners

The energy absorption behaviour of composite stiffeners subjected to axial compression has been investigated. A semi-empirical analysis methodology has been developed for prediction of the energy absorption capability of composite stiffeners based on crush tests of flat plate specimens and an understanding of the fundamentals of the energy absorption process. Flat plate, angle and channel specimens were fabricated from T650-35/F584 graphite/epoxy plain-weave fabric using five different lay-ups that consisted of varying percentages of 45° and 0° plies. The specimens were crush tested under axial compression, and measured levels of sustained crushing stress were compared with model predictions.     

The Effects of Triggering Mechanisms on the Energy Absorption Capability of Circular Jute/Epoxy Composite Tubes under Quasi-Static Axial Loading

The usage of composite materials have been improving over the years due to its superior mechanical properties such as high tensile strength, high energy absorption capability, and corrosion resistance. In this present study, the energy absorption capability of circular jute/epoxy composite tubes were tested and evaluated. To induce the progressive crushing of the composite tubes, four different types of triggering mechanisms were used which were the non-trigger, single chamfered trigger, double chamfered trigger and tulip trigger. Quasi-static axial loading test was carried out to understand the deformation patterns and the load-displacement characteristics for each composite tube. Besides that, the influence of energy absorption, crush force efficiency, peak load, mean load and load-displacement history were examined and discussed. The primary results displayed a significant influence on the energy absorption capability provided that stable progressive crushing occurred mostly in the triggered tubes compared to the non-triggered tubes. Overall, the tulip trigger configuration attributed the highest energy absorption.     

Improving the bending strength and energy absorption of corrugated sandwich composite structure

The bending strength, stiffness and energy absorption of corrugated sandwich composite structure were investigated to explore novel designs of lightweight load-bearing structures that are capable of energy absorption in transportation vehicles. Key design parameters that were considered include fibre type, corrugation angle, core-sheet thickness, bond length between core and face-sheets, and foam inserts. The results revealed that the hybridization of glass fibres and carbon fibres (50:50) in face-sheets was able to achieve the equivalent specific bending strength as the facet-sheets made entirely of carbon fibre composites. Increasing the corrugation angle and the core sheet thickness improved the specific bending strength of the sandwich structure, while increasing the bond length led to a reduction in the specific bending strength. The hybrid composite coupons with foam insertion showed medium energy absorption, ranging between the glass fibre and the carbon fibre composite coupons, but the highest crush force efficiency among all designs.     

Fatigue behaviour of alumina-fibre-reinforced epoxy resin composite pipes under tensile and compressive loading conditions

Fatigue tests have been conducted on composites consisting of epoxy resin reinforced with alumina fibres (AFRP) under cyclic tensile and compressive loading conditions with the variation of fibre orientation. The behaviour of the stress/strain curve for a ±45° sample is different from those for the ±15 and ±25° composite specimens, whereas, the monotonic strength decreases with increase in fibre angle for all specimens, which satisfies the maximum stress failure criterion. Fatigue results show that the applied stress decreases with an increase in the number of cycles to failure under both loading conditions for all composite pipes, but for the ±45° sample the decrease was slow. The results of fatigue tests on a macroscopic level indicate that the matrix crack density slowly increased with increase in the normalized number of cycles to failure in all the specimens. The normalized apparent stiffness therefore falls with an increase of the normalized number of cycles to failure. However, the maximum stress decreased with the increase in the number of cycles to failure in the case of the ±45° pipe. Finally, it is observed that matrix cracking and delaminations are occurring in the ±45° sample whereas delamination and fibre buckling are appearing in the ±15 and ±25° samples.     

A numerical study on the quasi-static axial crush characteristics of square aluminum–composite hybrid tubes

In this paper, we describe a numerical investigation on the quasi-static axial crush performance of aluminum–composite hybrid tubes containing a filament-wound E-glass fiber-reinforced epoxy over-wrap around square aluminum tubes. The fiber orientation angle in the overwrap was varied between [±30°] and [90°] with respect to the tube’s axis. The quasi-static axial crush resistance of the hybrid tubes are compared in terms of the maximum load, mean crush load, crush energy and specific energy absorption. The deformation modes of these tubes are also described. An empirical equation is proposed for predicting the mean crush force of hybrid tubes.     

Influence of winding angle on the strength and deformation of filament-wound composite tubes subjected to uniaxial and biaxial loads

Experimental data are presented to show the effects of winding angle on the strength of 100 mm diameter, 1 mm thick, filament wound E-glass fibre reinforced epoxy resin tubes tested under various combinations of internal pressure and axial tension or compression. Leakage and fracture strength envelopes are presented for ±45°, ±55° and ±75° winding angle tubes subjected to a wide range of different biaxial membrane stress states. Strengths range from 30 to 1250 MPa. Axial compression test results for tubes with wall thicknesses ranging from 1 to 3·6 mm establish the influence of shell buckling. Stress/strain curves up to fracture under three different types of loading show the effects of the winding angle on elastic constants and on nonlinear stress strain behaviour.     

Composite sandwich structures with nested inserts for energy absorption application

Polymer composite sandwich structures are promising candidate structures for reducing vehicle mass, thereby improving the fuel economics. Nonetheless, to fully explore this material as the primary structure and energy absorber in vehicles, it is important to understand the energy absorption capability of this material. Hence, in the present work, comprehensive experimental investigation on the response of composite sandwich structures to quasi-static compression has been carried out. The crashworthiness parameters, namely the peak force, absorbed crash energy, specific absorbed energy, average crushing force and crush force efficiency of various types of composite sandwich structures were investigated in a series of edgewise axial compression tests. The tested composite sandwich specimens were fabricated from glass and carbon fiber with epoxy resin. Four distinct modes of failure were observed and recorded. The primary mode of failure observed was progressive crushing with high energy absorption capability. The optimized design in this study had a specific energy absorption capability of 47.1 kJ/kg with a good crush force efficiency of 0.77, higher than conventional metals.     

Prediction of energy absorption in composite stiffeners

The energy absorption behavior of composite stiffeners subjected to axial compression has been investigated. Flat plate, angle, and channel specimens were fabricated of T650-35/F584 graphite/epoxy plain-weave fabric and were crush tested under axial compression. A nonlinear finite element approach was used to model the sustained crushing of the flat plate specimens, and a progressive failure model was implemented as part of the finite element analysis to enable investigation of the fundamental mechanisms involved in the crushing behavior. The progressive failure model was based on linear elastic fracture mechanics for prediction of crack growth and a set of failure criteria for predicting fiber/matrix failures that occurred as a result of large deformations. Friction between the specimen and the crushing surface was included in the model. A semi-empirical analysis methodology was developed for prediction of the energy absorption capability of composite stiffeners based on crush tests of flat plate specimens and an understanding of the fundamentals of the energy absorption process.     

Experimental and analytical assessment of axial crushing of circular hybrid tubes under quasi-static load

In the present article, axial crushing behavior of circular aluminum/glass–epoxy hybrid tubes is studied experimentally and analytically. 48 quasi-static axial crushing experiments are carried out on bare metal and hybrid tubes to evaluate the effect of different parameters such as metal and composite wall thicknesses and stacking sequence of composite layers on the crashworthiness characteristics. The specimens are made in two types of layups including angle ply pattern [±θ]_s and multi angle ply pattern (different ply angles). The experimental results reveal that stacking sequence has a considerable effect on crashworthiness characteristics, for example for layup [90/0/0/90], the absorbed energy is more than three times of aluminum tube with the same aluminum wall thickness. Also the aforementioned layup has better energy absorption compared to [90/90/90/90] which has been previously proposed as the best layup.     

铺层顺序对复合材料薄壁圆管轴向压溃吸能特性的影响研究

采用仿真和试验相结合的方法探讨复合材料薄壁圆管在准静态轴向压缩载荷下的失效吸能特性和吸能机理。首先,建立复合材料薄壁圆管"层合壳"有限元模型,通过显式动力学方法求解其在准静态轴向载荷下的压溃失效力学行为。仿真与试验结果在圆管轴向压溃变形过程、初始峰值载荷、平均压溃载荷及比吸能等主要吸能参数上具有很好的一致性,验证了"层合壳"复合材料圆管有限元模型和建模方法的有效性。其次,采用解析模型与仿真分析方法分别对[0/90]_3s、[0/90/0₂/90₂]_s、[0₃/90₃]_s三种不同铺层顺序的复合材料圆管的屈曲载荷与吸能特性进行了对比,进一步分析了铺层顺序对圆管失效吸能特性的影响。研究表明,0°与90°铺层交替程度对复合材料圆管的吸能特性影响较大,保证纤维失效方式在结构宏观失效中占主导地位能够提高材料失效吸收能量。     

Comparative research on the crashworthiness characteristics of woven natural silk/epoxy composite tubes

This study investigated the energy absorption response of triggered and non-triggered woven natural silk/epoxy composite rectangular tubes subjected to an axial quasi-static crushing test. The rectangular composite tubes were prepared by the hand lay-up technique using 12 layers of silk fabric with a thickness of 1.7 mm and tube lengths of 50, 80, and 120 mm. The parameters measured were peak load, energy absorption, and specific energy absorption (SEA). In both triggered and non-triggered tubes, the SEA values decreased with increasing length of the composite specimen. On the contrary, total energy absorption increased with increasing length of the composite specimen. The peak load in triggered specimens is nearly half of that in non-triggered specimens. Deformation morphology shows that the specimens failed in two distinct modes: local buckling and mid-length buckling. The non-triggered composite tubes exhibited catastrophic failure, whereas the triggered composite tubes only exhibited progressive failure.