Abstract
Thin-walled structures like crash boxes may be used as energy absorbers in the automotive chassis. There have been lots of investigations about the behavior of these parts during frontal crashes. Previous researches show that thin-walled circular tube has the highest energy absorption among different structures. In this study, cutting and folding modes of extruded aluminum tubes (EN-7018 T6) with 50 mm diameter, lengths of 300 and 400 mm and thicknesses of 2, 2.5 and 3 mm are compared when axial impacts with velocities of 6, 8 and 10 m.s-1 are applied to them. Cutting tools of 4 and 6 blades are used to provide the cutting mode. Effective parameters of energy absorbers including crush force efficiency, specific energy absorption and maximum axial load are modeled numerically with the help of Hooputra’s ductile damage criterion and are compared to each other for three cases of aluminum tube folding between two rigid plates and tube rupture by using 4 and 6 blades cutting tools. The analyses show that the tube rupture by the 6 blades cutting tool is better than the other two in the case of energy absorption. Furthermore, the results demonstrate that tube cutting with the help of multi-blades cutting tools is more stable, controllable and predictable than tube folding.
Highlights
Thin-walled beams are widely used as crash absorbers in the automotive chassis
Damage numerical analyses of a circular tube are carried out based on ductile failure criterion to accurately obtain crashworthiness simulation results
The impact velocity has direct relationship with maximum displacement, total energy absorption and specific energy absorption for different tube dimensions and various impact velocities during tube folding between two flat rigid plates and tube rupture by 4 and 6 blades cutting tools
Summary
Thin-walled beams are widely used as crash absorbers in the automotive chassis. Such kinds of structures are frequently used in the vehicle front parts. Majumder et al [9] investigated experimentally a cutting deformation mode of AA6061 T4 and T6 round extrusions with two different wall thicknesses of 1.587 and 3.175 mm under quasi-static loading conditions. Three cases are modeled numerically: tube folding between two rigid flat plates and tube rupture with the help of 4 blades and 6 blades cutting tools when the impact is applied axially to the aluminum tube. The results of this modeling are obtained and compared for different impact velocities and various geometries of the aluminum tube.
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
