Cook Model Research Articles

Internal cooling system effects to heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V

Internal cooling systems are essential for turning operations to improve the efficiency and quality of the machining process. In this paper, application of the virtual machining system is developed to analyze the effects of internal cooling systems on heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V. The cutting forces as well as cutting temperature along machining paths are simulated in the virtual machining system to predict and analyze the effects of internal cooling system to the heat transfer and tool wear during turning operations. The coolant flow inside the internal cooling channels of a rotating cutting tool is simulated using computational fluid dynamics. Next, utilizing the modified Johnson–Cook model, the cutting temperature during turning operations is determined. The finite element method is employed to predict tool wear by applying the Takeyama–Murata analytical method. To validate the study, experimental works are implemented using turning machine tool. The cutting settings during experimental works are feed rate of 0.3 mm/rev, depth of cut of 2 mm, and cutting speed of 75 m/min. Thus, using the proposed virtual machining system, the performance of internal cooling system can be enhanced to increase cutting tool life and surface quality of machined parts in turning operations.

A FEM-based model for failure initiation in the microstructure of gray cast iron under uniaxial compression

PurposeThe purpose of this study was to validate the feasibility of the proposed microstructure-based model by comparing the simulation results with experimental data. The study also aimed to investigate the relationship between the orientation of graphite flakes and the failure behavior of the material under compressive loads as well as the effect of image size on the accuracy of stress–strain behavior predictions.Design/methodology/approachThis paper presents a microstructure-based model that utilizes the finite element method (FEM) combined with representative volume elements (RVE) to simulate the hardening and failure behavior of ferrite-pearlite matrix gray cast iron under uniaxial loading conditions. The material was first analyzed using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) to identify the different phases and their characteristics. High-resolution SEM images of the undeformed material microstructure were then converted into finite element meshes using OOF2 software. The Johnson–Cook (J–C) model, along with a damage model, was employed in Abaqus FEA software to estimate the elastic and elastoplastic behavior under assumed plane stress conditions.FindingsThe findings indicate that crack initiation and propagation in gray cast iron begin at the interface between graphite particles and the pearlitic matrix, with microcrack networks extending into the metal matrix, eventually coalescing to cause material failure. The ferritic phase within the material contributes some ductility, thereby delaying crack initiation.Originality/valueThis study introduces a novel approach by integrating microstructural analysis with FEM and RVE techniques to accurately model the hardening and failure behavior of gray cast iron under uniaxial loading. The incorporation of high-resolution SEM images into finite element meshes, combined with the J–C model and damage assessment in Abaqus, provides a comprehensive method for predicting material performance. This approach enhances the understanding of the microstructural influences on crack initiation and propagation, offering valuable insights for improving the design and durability of gray cast iron components.

A modified Holmquist‒Johnson‒Cook (HJC) constitutive model and its application to numerical simulations of explosions and impacts in rock materials

The Holmquist‒Johnson‒Cook (HJC) model is a commonly used constitutive model for simulations of the dynamic response and damage characteristics of geotechnical materials under explosions and impacts. However, certain deficiencies in its strength, strain rate, and damage models limit its computational effectiveness. Therefore, this paper first introduced the constitutive relation of the HJC. Then, the single-strength equation of the original HJC was improved by adopting three limiting surfaces and considering the impact of the Lode-angle on the yield surface. The hyperbolic tangent function was employed to model the rate effect, and the recommended strain rate parameters for rock materials were provided. Furthermore, an exponential strain softening function-based tensile damage equation was introduced to address tensile damage under negative pressure. On this basis, a method for determining parameters for the modified HJC in rock materials was proposed. Finally, the modified model was incorporated into the LS-DYNA material library using secondary development techniques, and multiple types of impact and explosion experiments on different types of rock materials were simulated using both the original and modified HJC. Additionally, the modified HJC was compared with several other modified HJC versions from various perspectives. It has been found that the simulation results of the modified HJC are in closer agreement with the experimental results than those of the original HJC. Compared to other modified HJC models, the modified HJC proposed in this paper offers a broader range of applications and a better compromise between computational efficiency and the number of parameters.

Optimization of Ti-3Al-2.5V titanium tubes by differential heating push-bending based on a modified Johnson−Cook constitutive model

This study addresses the challenges associated with the difficult formation and low quality of formed Ti-3Al-2.5 V titanium alloy thin-walled tubes with small bending radii (r / D < 1.5, where r is the bending radius, D is the outer diameter of the tube) by proposing a differential heating push-bending (DHP-B) forming approach. Initially, the stress−strain curves of Ti-3Al-2.5 V at various strain rates and temperatures were obtained through high-temperature uniaxial tensile tests. Subsequently, a modified Johnson−Cook (JC) model for Ti-3Al-2.5 V within the temperature range of 25℃ to 800℃ was developed to enhance the accuracy of the finite element model. Based on the static implicit and dynamic explicit algorithms, a thermomechanically coupled finite element model for differential heating push-bending of titanium alloy thin-walled tubes has been established. Taking the heating temperature, friction coefficient, counterthrust force and rubber block thickness as the optimization parameters, the prediction model of the maximum wall thinning rate and thickening rate is obtained by using the response surface method, and the best parameter combination is obtained via the NSGA-II algorithm and the minimum distance selection method, which realizes the optimization of differential heating push-bending parameters, as verified by experiments in which the maximum wall-thinning rate is reduced to 9 %, and the maximum wall thickness thickening rate is reduced to 14.2 %, which improves the forming quality of the titanium tube.

Insights into Machining Techniques for Additively Manufactured Ti6Al4V Alloy: A Comprehensive Review

Investigation into the post-processing machinability of Ti6Al4V alloy is increasingly crucial in the manufacturing industry, particularly in the machining of additively manufactured (AM) Ti6Al4V alloy to ensure effective machining parameters. This review article summarizes various AM techniques and machining processes for Ti6Al4V alloy. It focuses on powder-based fusion AM techniques such as electron beam melting (EBM), selected laser melting (SLM), and direct metal deposition (DMD). The review addresses key aspects of machining Ti6Al4V alloy, including machining parameters, residual stress effects, hardness, microstructural changes, and surface defects introduced during the additive manufacturing (AM) process. Additionally, it covers the qualification process for machined components and the optimization of cutting parameters. It also examines the application of finite element analysis (FEA) in post-processing methods for Ti6Al4V alloy. The review reveals a scarcity of articles addressing the significance of post-processing methods and the qualification process for machined parts of Ti6Al4V alloy fabricated using such AM techniques. Consequently, this article focuses on the AM-based techniques for Ti6Al4V alloy parts to evaluate and understand the performance of the Johnson–Cook (J–C) model in predicting flow stress and cutting forces during machining of the alloy.

Barrel rifling node offset detection and subsequent optimization based on thin film in-mold decoration characteristics of the Johnson–Cook model

In this paper, a nodal detection method for the detection and optimization of barrel helix offsets is proposed. The barrel used in this experiment is a 6-helix barrel. Moreover, the special properties of the film of Polyetheretherketone (PEEK) material are used to cover the surface of the barrel helix with a virtual in-mold decoration (IMD) film, and the unique nature of the film die offset in the IMD is utilized to detect the position of the barrel helix. The area with a large die index is the area with a large helix offset in the barrel, and the IMD die index is introduced to quantify the data. The IMD die index is used to determine the helix offset of the damaged barrel. The novelty of this work is that each node can use the die index to efficiently detect the position of the barrel helix deviation, carry out subsequent optimization and repair work through the optimization of the injection molding parameters and the design optimization of the barrel and verify the experiment by comparing the results. Through the steady-state simulation research mode, different permutations and combinations of the two process parameters are simulated to study their effects. Quantitative reference indicators include but are not limited to dependent variables such as the fluid flow velocity, shear rate, temperature distribution and phase transition, and the shear heating process of the injection screw is taken into account in the mold flow analysis to ensure that the die index value is more accurate. It can be seen from the analysis results that the temperature of the barrel changes after the groove depth and groove width are changed, and the effect ratio of the groove depth is lower than that of the groove width in the same degree of size change.

Investigations of three-dimensional fiber orientation on mechanical impact behavior of short glass-fiber-reinforced PEEK composites

This work presents experimental and numerical investigations of three-dimensional (3D) fiber orientation on mechanical impact behavior of short glass-fiber-reinforced polyether ether ketone (SGFR PEEK) composites. The incorporation of short fibers significantly enhances the stiffness and strength of the composites while reducing the ductility, thereby, making the study of their impact response essential. To this end, we firstly manufactured the composite components using injection molding, and used the micro-computed tomography (µCT) to measure the fiber orientation distribution in 3D space for mechanical behavior prediction. Then, by studying the molded components across the thickness based on the actual observation, a distinct laminate structure with seven layers was quantitatively evaluated. A representative volume element (RVE) micromechanical computational method was developed and compared with the experimental results. Furthermore, homogenization method with the periodic boundary condition was implemented to evaluate the effective mechanical properties of the molded components. Finally, the phenomenological Johnson Cook (JC) model with fracture behavior was conducted to analyze the impact response of the injected components with different fiber orientation distributions. The new framework is demonstrated by acceptable energy absorption capability prediction of the SGFR PEEK composites.

Research on Dynamic Mechanical Behavior of Reinforcing Steel Under Ultrahigh Strain Rate

The strain rate effect significantly influences the dynamic mechanical behavior of reinforcing steel under impact loads. To investigate the effect of strain rate on the dynamic mechanical behavior of reinforcing steel, this study conducts dynamic compression tests on four types of reinforcing steel using a Split Hopkinson pressure bar. The results show that there is a significant strain rate effect on the reinforcing steel when the strain rate reaches 103–104 s−1. The experimental results are analyzed using the Johnson–Cook model (J–C model), and the original model is modified based on the error between the model predictions and the experimental results. The results indicate that the modified J–C model, which includes an enhanced strain rate effect term, better predicts the dynamic mechanical behavior of reinforcing steel at ultrahigh strain rates.

Determination and Verification of the Johnson–Cook Constitutive Model Parameters in the Precision Machining of Ti6Al4V Alloy

Numerical simulations of the cutting process play a key role in manufacturing and cost optimization. Inherent in finite element analysis (FEA) simulations is the correct description of material behavior during machining. For this purpose, various material models are used to describe the behavior of the material in the range of high deformation, high temperature values, and high strain rates. Very often the Johnson–Cook (JC) material model is used for this purpose; however, the correct determination of the material constants of this model is a key aspect. Therefore, this paper presents a procedure for determining the material constants of the JC model using an analytical method based on normalized tensile and compression testing of the material for different strain rates over a wide temperature range. After determining the material constants, the authors conducted numerical simulations of the orthogonal turning of Ti6Al4V titanium alloy using the obtained constants. Validation of the obtained results with those obtained in experimental studies was also carried out. The outcomes demonstrated that the difference between FEM simulation and experimental tests did not exceed 0.02 mm (14%) in the case of chip thickness,. Much smaller differences were obtained for the temperature in the cutting zone, where the maximum difference was about 45 °C (4%). Comparing the components of the cutting force, we found that, in the case of the main cutting force, in most cases, the differences did not exceed 70 N (8%). After the verification of the obtained results, it was also found that the determined material constants of the Johnson–Cook model can be successfully used in FEM modeling of the cutting process of Ti6Al4V titanium alloy for the adopted range of values of technological parameters.

Pore collapse, shear bands, and hotspots using atomistics-consistent continuum models for RDX (1,3,5-trinitro-1,3,5-triazinane): Comparison with molecular dynamics calculations

Shock-induced energy localization is a crucial mechanism for determining shock sensitivity of energetic materials (EMs). Hotspots, i.e., localized areas of elevated temperature, arise when shocks interact with defects (cracks, pores, and interfaces) in the EM microstructure. The ignition and growth of hotspots in a shocked energetic material contribute to rapid chemical reactions that can couple with the passing shock wave, potentially leading to a self-sustained detonation wave. Predictive models for shock-to-detonation transition must correctly capture hotspot dynamics, which demands high-fidelity material models for meso-scale calculations. In this work, we deploy atomistics-guided material models for the energetic crystal RDX (1,3,5-trinitro-1,3,5-triazinane) and perform tandem continuum and all-atom molecular dynamics (MD) simulations. The computational setup for the continuum and MD simulations are nearly identical. The material models used for the calculations are derived from MD data, particularly the equations of state, rate-dependent Johnson–Cook strength model, and pressure-dependent shear modulus and melting temperature. We show that a modified Johnson–Cook model that accounts for shear-induced localization at the pore surface is necessary to represent well—relative to MD as the ground truth—the inelastic response of the crystal under a range of shock conditions. A head-to-head comparison of continuum and atomistic calculations across several metrics of pore collapse and energy deposition demonstrates that the continuum calculations are in good overall agreement with MD. Therefore, this work provides improved RDX material models to perform physically accurate meso-scale simulations, to enhance understanding of hot spot formation, and to use meso-scale hot spot data to inform macro-scale shock simulations.

Raft-like lipid mixtures in the highly coarse-grained Cooke membrane model.

Lipid rafts are nanoscopic assemblies of sphingolipids, cholesterol, and specific membrane proteins. They are believed to underlie the experimentally observed lateral heterogeneity of eukaryotic plasma membranes and implicated in many cellular processes, such as signaling and trafficking. Ternary model membranes consisting of saturated lipids, unsaturated lipids, and cholesterol are common proxies because they exhibit phase coexistence between a liquid-ordered (lo) and liquid-disordered (ld) phase and an associated critical point. However, plasma membranes are also asymmetric in terms of lipid type, lipid abundance, leaflet tension, and corresponding cholesterol distribution, suggesting that rafts cannot be examined separately from questions about elasticity, curvature torques, and internal mechanical stresses. Unfortunately, it is challenging to capture this wide range of physical phenomenology in a single model that can access sufficiently long length- and time scales. Here we extend the highly coarse-grained Cooke model for lipids, which has been extensively characterized on the curvature-elastic front, to also represent raft-like lo/ld mixing thermodynamics. In particular, we capture the shape and tie lines of a coexistence region that narrows upon cholesterol addition, terminates at a critical point, and has coexisting phases that reflect key differences in membrane order and lipid packing. We furthermore examine elasticity and lipid diffusion for both phase separated and pure systems and how they change upon the addition of cholesterol. We anticipate that this model will enable significant insight into lo/ld phase separation and the associated question of lipid rafts for membranes that have compositionally distinct leaflets that are likely under differential stress-like the plasma membrane.

Experimental Determination and Simulation Validation: Johnson–Cook Model Parameters and Grinding Simulation of 06Cr18Ni11Ti Stainless Steel Welds

Hydrogen permeation resistance in the welded region of 06Cr18Ni11Ti steel is relatively weak due to surface defects, which need high integrity surface machining. The parameters of the welding material for 06Cr18Ni11Ti steel are currently unavailable, which causes some inconvenience for simulation studies. To fill the lack of 06Cr18Ni11Ti steel weld material parameters in the relevant literature at the present stage, the quasi-static tensile test at different strain rates and notch specimen tensile tests were conducted in this paper and determined the Johnson–Cook (J-C) constitutive model parameters and Johnson–Cook failure model parameters. Subsequently, a multi-grain grinding simulation model was built based on W-M fractal dimension theory by using the determined material parameters. The influence of processing parameters on grinding heat was analyzed. Grinding experiments were conducted to analyze the influence of processing parameters on grinding heat and grinding force. By comparing the simulation and experimental results, it is revealed that the average error is 9.37%, indicating relatively small discrepancy. It is demonstrated that the grinding simulation model built in this paper could efficiently simulate the grinding process, and the determined weld material parameters of 06Cr18Ni11Ti steel have been verified to possess high accuracy and reliability.

Dynamic mechanical properties and uni-axial constitutive model of S30408 stainless steel

This paper investigates its mechanical properties at different strain rates and the uni-axial constitutive model of S30408 (S30408 known as 1.4301 in EN10088:1, 304 in ASTM standard) stainless steel. Firstly, the tensile and compressive mechanical properties of S30408 stainless steel were tested at four strain rates (0.001 s−1, 1000 s−1, 3000 s−1, 5000 s−1) by performing quasi-static tests as well as split Hopkinson tension bar (SHTB) and split Hopkinson pressure bar (SHPB) tests. Based on the tests, the stress-strain curves of S30408 stainless steel under tensile and compressive conditions at different strain rates were obtained. The results show that S30408 stainless steel revealed a significant strain rate strengthening effect, and there were some differences in the mechanical properties of S30408 stainless steel in tension and compression under different strain rates. Then based on these test results, a modified Johnson–Cook model was established under tensile and compression conditions. The accuracy of the proposed modified Johnson-Cook model was verified by the finite element software LS-DYNA. The modified model can provide a reference for the study of mechanical properties and computational simulation of S30408 stainless steel under high strain rate conditions such as impact and blast load.

A Dynamic Damage Constitutive Model of Rock-like Materials Based on Elastic Tensile Strain

To accurately characterize the damage of rock-like materials under simultaneous or alternating tensile and compressive loading, a dynamic damage constitutive model for rock-like materials based on elastic tensile strain is developed by integrating the classical compressive plastic damage model and the tensile elastic damage model. The model is based on the Holmquist–Johnson–Cook (HJC) and Kuszmaul (KUS) models, categorizing the element stress state into tensile and compressive states through positive and negative elastic volumetric strain. It utilizes elastic tensile strain to enhance the calculation method for tensile cracks, determining the tensile strength of the principal direction based on the contribution rate of tensile principal stress for uniaxial/multiaxial loading. Additionally, it establishes a maximum elastic tensile strain rate function to rectify the model’s effect on the tensile strain rate. Through the LS-DYNA subroutine development, the model proficiently delineates the distribution of ring-shaped cracks on the frontal side and strip-shaped cracks on the rear side of the reinforced concrete slab subjected to impact loading. Numerical simulations demonstrate that the model provides more accurate damage prediction results for stress conditions involving simultaneous or alternating compression and tension, offering valuable insights for damage analysis in engineering blasting or impact penetration.

Blast performance of RC columns with different levels of concrete grades and reinforcing ratios

AbstractThe present article aims to study the behavior of RC columns under blast loading. A nonlinear dynamic Three‐Dimensional (3D) Finite Element FE model‐based explicit solver available in ABAQUS Software is used. A parametric study is investigated to enhance the blast resistance of RC columns under three different scaled distances z of an explosion, that is, 0.23, 0.5, and 1.07 m/kg1/3 for close, intermediate, and Far in‐distance. In addition, three levels of concrete grades are used, which are Normal Strength Concrete (NSC), High Strength Concrete (HSC), and Ultra High‐Performance Concrete (UHPC). The study also considers Three reinforcement ratios for longitudinal and transverse reinforcement ratios of (ρL = 1.28%, 2.4%, and 3.1%) and (ρs = 0.6%, 0.9%, and 1.35%), respectively. Further, three different Axial Load Ratios, ALR = 0.01, 0.2, and 0.4, are considered to examine the effect of increasing ALR on the RC column under close explosion. For more investigation, the parametric analysis considers two geometrical shapes of RC columns (square and circular). The material behaviors of concrete and reinforcing steel bars are represented using Concrete Damage Plasticity (CDP) and Johnson–Cook (J–C) models, respectively, available in ABAQUS Software. The FE model has been initially validated against experimental study. The FE‐predicted deflection and damage were observed and agreed with the practical cases. In addition, the parametric study's results demonstrate that the RC column's blast deflection is significantly reduced with increasing reinforcement ratios. However, increasing concrete grade could efficiently reduce blast damage and deflection. Furthermore, compared with NSC, UHPC significantly reduced maximum damage and deflection by around 60% for square and 55% for circular columns, respectively.

Multi-stage Johnson–Cook Model for Collision Analysis: Impact Experiments and Simulations

Multi-stage Johnson–Cook Model for Collision Analysis: Impact Experiments and Simulations

Dynamic tensile characteristics of elliptically shaped Ni8Ti9Cr1 rings

Thin-walled tubes with elliptically shaped annular sections are widely applied in fuel ducts and exhaust pipes. However, the tensile mechanical properties of these structures have remained elusive due to the lack of accurate testing methods. This study aims to fill this gap by establishing circumferential tensile testing methods for static and dynamic conditions by employing a split Hopkinson tensile bar and an electronic universal tensile machine. The quasistatic and dynamic tensile characteristics of two distinct elliptically shaped Ni8Ti9Cr1 rings with different aspect ratios were investigated at room temperature, revealing a significant loading rate effect. The tensile curves exhibited considerable fluctuations, which diminshed as aspect ratios decreased. These fluctuations were attributed to stress waves propagating back and forth between the specimen, the clamp, and the bars, causing superimposition. The Johnson‒Cook (JC) model was established based on the experimental results and then incorporated into the finite element model to gain deep insights into the mechanical responses of the Ni8Ti9Cr1 rings under tension. Our findings reveal that dynamic tensile testing of elliptically shaped Ni8Ti9Cr1 rings induces a complex stress state, which leads to nonuniform necking effects and structural vibrations, revealing complex behaviors previously unexplored. This investigation significantly advances the understanding of quasistatic and dynamic tensile responses in elliptically shaped ring structures, shedding light on their mechanical intricacies across varying conditions.

Minimization of residual stress, surface roughness and tool wear in Electro Discharge Machining of inconel 625

Electro Discharge Machining (EDM) is a well-known non-traditional machining technique which is widely used to make die castings and turbine blades out of difficult-to-cut materials like Inconel 625. The machined part's surface quality and dimensional accuracy are affected by the EDM electrode's wear. Moreover, surface roughness and residual stress augmentation of EDM-machined components can reduce the workpiece's lifespan by decreasing the fatigue life of machined parts. To enhance the precision and durability of EDM machined components, residual stress, tool wear, and surface roughness should be evaluated and minimized. The majority of published research works for the assessment and optimization of EDM machining parameters are based on experimental works which are limited to testing, workpiece materials, and machining conditions. In order to improve the quality of machined surfaces and reduce tool wear and residual stress during Inconel 625 EDM processes, a virtual machining approach has been developed in the research work. To predict the cutting temperature during EDM operations, the modified Johnson Cook model of Inconel alloys is used. The finite element approach is then used to calculate the generated residual stress during the EDM process. The proposed virtual machining approach is also applied in order to predict the surface roughness of EDM machined parts. To minimize the residual stress, tool wear, and surface roughness during EDM operations of Inconel 625, the machining parameters of gap voltage, peak current, pulse-off time, and pulse-on time are optimized using the Taguchi optimization approach. Experiments and simulations are then conducted to verify the developed virtual machining system in the study. So, using the optimal machining parameters, the residual stress, surface roughness of machined items and wear of EDM electrode are minimized by 24.5 %, 25.4 %, and 25.4 % respectively. Thus, the quality and reliability of components made using EDM processes may be enhanced by the suggested virtual machining system.

A modified Johnson–Cook model for the plastic behavior of metals in ultrasonic vibration-assisted upsetting processes

In this work, we present a constitutive description of the plastic behavior of the metals and alloys under Ultrasonic Vibration (UV). When UV is imposed, it induces a softening effect on the plastic deformation of metals and alloys, referred to as the acoustoplastic phenomenon. The volumetric softening mechanism of the acoustoplasticity must consider stress superposition and acoustic softening. Taking the Johnson–Cook (JC) constitutive model as the reference for metal thermo-plasticity, the flow stress reduction due to UV is introduced by three types of softening terms: subtractive, multiplicative, and coupled. Those different configurations will be quantified via physical and phenomenological assumptions. For the study and validation of the proposed constitutive models, we focus on a well-known material, 6063 aluminum alloy. The ultrasonic vibration is modeled by an assisted upsetting process of an aluminum billet and compared with experiments. The impact of variations of the strain rate, ultrasonic amplitude, and frequency on the softening behavior of the models are analyzed and compared with available experimental results. We find out that the subtractive and coupled models agreed well with the experimental results showing the errors ranging from 2.4–4.8% and 4.4%–8%, respectively. However, the predictive ability of the multiplicative model exhibits large discrepancies at the low stage of strains following the acceptable predictions at high stains. By understanding the impact of the UV on the acoustoplastic deformation of the metals and alloys we can establish a reliable theoretical framework for prospective numerical studies of the UV-assisted manufacturing processes which is the goal of the current research presented here.

Numerical-experimental analysis of laser-welded small energy absorbers with direct impact Hopkinson method

This research paper presents a comprehensive numerical-experimental analysis of the phenomena observed during the compression of small energy absorbers (EAs) with dimensions 23 × 23 mm and a thickness of 0.6 mm. This study uses the direct impact Hopkinson (DIH) method. The locus is the detailed prediction of the strength of laser-welded joints in terms of energy absorption under both quasi-static and dynamic loading conditions. Furthermore, the paper explores the potential utility of the described methodology for modeling and predicting the failure mechanisms of small energy absorbers. This investigation delves into key factors that affect the distribution of cracks in deformed energy absorbers. These include: the detail of the reproduction of the absorber geometry, the impact of finite element formulations and modeling method (2D/3D elements) and the complexity of the material model for propagated cracks. Two material models are considered, the simplified Johnson–Cook model and the tabulated Johnson-Cook with Hockett–Shelby extrapolation model, which incorporate linear damage dependent on the stress triaxiality and Lode angle. The study also highlights the advantages and disadvantages of the DIH test method. Some features cannot be effectively observed through experimental testing alone. The experimental procedure involved initial testing and calibration of the material models for both the parent material and the welded joints at three different strain rates. Subsequently, the validated energy absorber models are subjected to static and dynamic crushing. The results are subsequently compared with the virtual results obtained using the gravity hammer method, which is a more readily accessible testing approach. Remarkably, a very high correlation between the numerical simulation and experimental data is observed, providing a comprehensive understanding of the research problem related to laser-welded absorbers.