Quasi-Static Axial Compression of Thi-Walled Circular Aluminium Tubes

International Journal of Mechanical Sciences 43 (2001) 21032123
Quasi-static axial compression of thin-walled

circular aluminium tubes
S.R. Guillow
a
, G. Lu
a,
, R.H. Grzebieta
b
a
School of Engineering and Science, Swinburne University of Technology, PO Box 218, Hawthorn,
Victoria 3122, Australia
b
Department of Civil Engineering, Monash University, Clayton, Victoria 3168, Australia
Received 5 October 2000; received in revised form 26 March 2001
Abstract
This paper presents further experimental investigations into axial compression of thin-walled circular
tubes, a classical problem studied for several decades. A total of 70 quasi-static tests were conducted
on circular 6060 aluminium tubes in the T5, as-received condition. The range of D}t considered was
expanded over previous studies to D}t=10450. Collapse modes were observed for L}D 610 and a mode
classication chart developed. The average crush force, F
AV
, was non-dimensionalised and an empirical
formula established as F
AV
}M
P
= 72.3(D}t)
0.32
. It was found that test results for both axi-symmetric
and non-symmetric modes lie on a single curve. Comprehensive comparisons have been made between
existing theories and our test results for F
AV
. This has revealed some shortcomings, suggesting that further
theoretical work may be required. It was found that the ratio of F
MAX
}F
AV
increased substantially with
an increase in the D}t ratio. The eect of lling aluminium tubes with dierent density polyurethane
foam was also briey examined. ? 2001 Elsevier Science Ltd. All rights reserved.
Keywords: Axial compression; Circular tube; Foam; Plastic collapse; Thin-walled tubes
0. Introduction
The behaviour of thin-walled metal tubes subjected to axial compression has been studied for
many years. Such tubes are frequently used as impact energy absorbers and Reid [1] has pre-
sented a general review of deformation mechanisms. Fig. 1 shows a typical forcedisplacement
curve for quasi-static loading. Generally speaking, the axial load rises until a rst buckle is
formed at a characteristic maximum force value, F
MAX
. This initial buckling behaviour is well
Corresponding author. Fax: +61-3-9214-8264.

E-mail address: glu@groupwise.swin.edu.au (G. Lu).
0020-7403/01/$ - see front matter ? 2001 Elsevier Science Ltd. All rights reserved.
PII: S0020- 7403(01)00031- 5
2104 S.R. Guillow et al. / International Journal of Mechanical Sciences 43 (2001) 21032123
Nomenclature
D average diameter
F
AV
average axial force
F
MAX
maximum axial force for rst peak
q acceleration due to gravity
H half-wavelength of fold
L length
M
P
full plastic bending moment of tube wall per unit length
m geometric eccentricity factori.e. ratio of outwards fold length to total fold length
N number of circumferential lobes (or corners) in non-symmetrical buckling
R average radius
t wall thickness of tube
J Vickers hardness number (kg}mm
2
)
o
e
eective crushing distance
j
f
density of foam
o
0
ow stress
o
0.2
0.2% proof stress
o
ult
ultimate tensile stress
Fig. 1. Typical loaddeection curve for an axially loaded thin-walled metal tube which collapsed by progressive
folding.
S.R. Guillow et al. / International Journal of Mechanical Sciences 43 (2001) 21032123 2105
Fig. 2. Examples of various collapse modes for thin-walled circular 6060-T5 aluminium tubes under axial load-
ing (more examples shown in Fig. 11): (a) axi-symmetric mode (D = 97.9 mm, t = 1.9 mm, L = 196 mm);
(b) non-symmetric mode (D = 96.5 mm, t = 0.54 mm, L = 386 mm); (c) mixed mode (D = 97.5 mm,
t = 1.5 mm, L = 350 mm).
known and will not be studied in depth here. Thereafter, depending on geometrical parameters
such as the ratios of D}t (diameter}thickness) and L}D (length}diameter) and also on material
properties, there are a variety of possible modes of collapse. Generally, collapse involves plastic
Fig. 3. Schematic axial view of non-symmetric or diamond collapse mode. Two cases are shown, N = 3 and 4
circumferential lobes.
buckling and the formation of progressive folds (whether axi-symmetric or non-symmetric). The
formation of these folds causes the characteristic uctuation in the axial force shown in Fig. 1.
This plastic collapse behaviour is of primary interest in this paper.
Experimentally the following modes of collapse have been observed and Fig. 2 shows some
typical examples : (i) axi-symmetric concertina bellowing, (ii) non-symmetric buckling (also
known as diamond or Yoshimura mode), with a variable number of circumferential lobes or
corners (refer to Fig. 3), (iii) mixed mode (combination of the two previous modes), (iv) Euler
or global buckling; and (v) other (simple compression, single folds, etc.).
Research on circular tubes in the past has generally concentrated on annealed aluminium
or steel tubes with D}t ratios between 10 and 150. It is common industrial practice to use
aluminium alloys in the heat treated as-received condition, but little research appears to have
addressed this particular case. Moreover, Gupta and Gupta [2] have identied metal temper as
one of the signicant factors in determining behaviour. Hence, it was decided to undertake an
experimental program to extend the range of research up to approximately D}t = 450 and to
test aluminium alloy tubes which were in the heat treated as-received condition. This work is
of potential application in civil, mechanical, marine and aeronautical engineering elds.
1. Review of previous studies
The following section summarises the available literature on the plastic collapse behaviour of
thin-walled circular metal tubes subject to quasi-static axial loading. It is arranged broadly in a
chronological order.
The rst signicant work to address the mechanics underlying the observed behaviour of
axially loaded thin-walled tubes was by Alexander [3]. He proposed a simple model for the
axi-symmetric fold pattern (refer to Fig. 4) based on experiments with metal tubes of D}t=
2989. At a global level, external work done was equated with internal work from bending at
three stationary plastic hinges and circumferential stretching of the metal between the hinges.
Fig. 4. Axi-symmetric collapse mechanism assumed by Alexander [3].
Thus the following theoretical equation was obtained for average crush force (axi-symmetric
folds):
F
AV
=Ko
o
t
1.5
D, (1)
where K is a constant and o
o
is the ow stress. Also, plastic half-wavelength, H (refer to
Fig. 4) was determined as follows:
H =C
Dt, (2)
where C is a constant. The experimental results observed by Alexander were generally in
agreement with the above two equations. Although simple, this model seems to reect the
underlying physical processes involved and many subsequent researchers have used it as a
starting point.
Pugsley and Macaulay [4] were among the rst researchers to consider the non-symmetric
folding mode, their study being largely empirical. Johnson et al. [5] attempted to develop a
theory for the non-symmetric mode based on the actual geometry of folding, with the tube
material at the mid-surface being considered inextensional. Hence they were able to develop
equations to predict average axial crush force, F
AV
. However, agreement between their model
and test results for P.V.C. tubes was not particularly good.
In 1978 Magee and Thornton [6] conducted a review of previous work by researchers who
had conducted axial crushing tests on circular metal tubes. By considering these collected data
they developed a number of empirical equations which involved the specic ultimate tensile
strength of the metal.
Andrews et al. [7] conducted a comprehensive series of tests on annealed aluminium alloy
tubes covering a wide range of D}t (460) and L}D (0.28.8). Consequently, they developed a
collapse mode classication chart which predicted the mode of collapse for any given D}t and
L}D combination.
Fig. 5. Axi-symmetric model used by Abramowicz and Jones [8,9]. H is the half-wavelength of the fold.
Abramowicz and Jones [8,9] conducted axial compression tests on a range of thin-walled cir-
cular and square steel tubes. They analytically considered both axi-symmetric and non-symmetric
modes. Abramowicz introduced the important concept of eective crushing distance, o
e
(refer
to Fig. 5), where a fold consisted of two equal radii segments of length H, curved in opposite
directions and the material had nite thickness.
For axi-symmetric folds, Abramowicz and Jones [9] developed the following equation in 1986
(and a similar one in 1984 [8]):
F
AV
M
P
=
[25.23
D}t + 15.09]
[0.86 0.568
t}D]
, (3)
where M
P
=o
o
(t
2
}4).
For non-symmetric folds, in 1984 [8] and 1986 [9] Abramowicz and Jones commenced with
two dierent starting relationships. Taking into account eective crushing distance, material
strain rate, etc., resulted in two dierent equations for average crush force. The simple relation-
ship developed in 1984 [8] applied regardless of the number of lobes:
F
AV
M
P
= 86.14
D
t
0.33
. (4)
However, this nding appears to have developed from work carried out by Wierzbicki and
Abramowicz [10] on rectangular rather than circular tubes. On the other hand, the relationship
Fig. 6. Collapse mechanism assumed by Grzebieta [12] for axi-symmetric mode.
Abramowicz and Jones derived in 1986 [9] was of the form
F
AV
M
P
=A
N1
D
t
+A
N2
, (5)
where A
N1
and A
N2
are constants which were a function of the number of lobes. For further
details the reader is directed to this reference.
In Refs. [8,9], Abramowicz and Jones observed that reasonable agreement existed between
predictions of average crush loads based on the above noted equations and their experimental
results for steel tubes with D}t = 965. In a subsequent work, Abramowicz and Jones [11]
reported on further tests and summarised their ndings for both static and dynamic loading
cases in two failure mode maps, adding to the previous work by Andrews et al. [7].
Gupta and Gupta [2] performed a series of quasi-static axial compression tests on thin-walled
aluminium and mild steel circular tubes in both the annealed and as-received conditions. They
combined all results and developed empirical equations for the average crushing force in terms
of the Vickers hardness and D}t.
Grzebieta [1214] used a strip method to analyse both axi-symmetric and non-symmetric
folding modes. He equated external work done with internal energy from horizontal, inclined and
travelling plastic hinges as well as stretching of the metal, to produce equations for determining
the instantaneous forces involved. Unfortunately, these equations do not yield simple expressions
for determining the average crush force.
Grzebietas collapse mechanism model for axi-symmetric mode (refer to Fig. 6) was a mod-
ication of Alexanders. A fold consisted of three equal lengths, two of which were curves
of equal radius and the third a straight line segment. For the non-symmetric mode Grzebieta
analysed the folds as a half-diamond mechanism. Grzebieta carried out static and dynamic tests
on steel tubes with D}t = 30300.
Fig. 7. Axi-symmetric model used by Wierzbicki [15] and Singace et al. [16,17].
Wierzbicki et al. [15] introduced a new model for the axi-symmetric collapse mechanism
(shown simplied in Fig. 7) which allows for both inwards and outwards radial displacement.
The geometry is governed by an arbitrary geometric eccentricity factor, m, which is dened
as the ratio of outward fold length to total fold length. By considering energy rate equations
Wierzbicki et al. [15] were able to develop equations for not only determining average crush
load but also a representative loaddeection history. The latter helped explain the experi-
mental observation that sometimes there are two force peaks during the formation of a single
fold.
Singace et al. [16,17] extended upon the previous work by Wierzbicki et al.. For the axi-
symmetric mode, they considered a global energy balance leading to an implicit equation for
m, which when solved gave a theoretical constant value of m = 0.65. In their second pa-
per [17], Singace et al. reported good experimental agreement with the predicted value of
0.65. Later, Singace et al. [18] re-considered the eccentricity factor, m, for the non-symmetric
mode case. From the results of experiments on a small range of circular metal tubes they de-
duced that the factor m was (surprisingly) approximately constant at m = 0.65 for this mode
also.
The equations developed by Singace et al. [17,18] for calculating average axial crush force
are as follows. For axi-symmetric mode:
F
AV
M
P
= 22.27
D
t
+ 5.632. (6)
For non-symmetric mode:
F
AV
M
P
=
3
N +
2
2
N
tan

2N
D
t
. (7)
One particular problem of interpretation arises with most theoretical equations developed for
non-symmetric mode collapse, for example Eq. (7). They require a knowledge of the number of
lobes, N, at a given D}t ratio. We have not found any published equation entirely satisfactory
in determining N.
Fig. 8. Experimental set-up.
With regard to energy absorption, it has been suggested that lling metal tubes with low-
density polyurethane foam (to provide wall stability) may be preferable to increasing the wall
thickness. Early investigations into the eectiveness of this foam lling method were conducted
by Thornton [19] and Lampinen and Jeryan [20]. Reid, Reddy and Gray [21] have conducted
experiments on the axial compression of thin-walled rectangular metal tubes which had been
lled with foam. Reddy and Wall [22] subsequently tested foam lled circular aluminium alloy
cans. Academic opinion appears to be divided about the relative benets of foam lling versus
increasing the wall thickness.
2. Test procedure and material properties
A series of approximately 70 axial compression tests were conducted under quasi-static condi-
tions. Tests were carried out on a SHIMADZU universal testing machine which applied the axial
load through at end platens (refer to Fig. 8). Cross-head speed was approximately 5 mm}min.
A LABTECH data-logger recorded the data digitally for later analysis.
The tubes tested were made from commercial quality extruded 6060 aluminium alloy in
the as-received, heat treated T5 condition. Mechanical properties were determined from tensile
testing of coupons cut from several tubes. Fig. 9 shows a stressstrain curve for a typical
tensile test specimen which had a 0.2% proof stress, o
0.2
, of 180 MPa, an ultimate stress, o
ult
,
of 212 MPa and a Vickers hardness, J, of 73 kg}mm
2
. By averaging results from several tensile
tests we were able to determine an empirical relation between the 0.2% proof stress and Vickers
hardness for this particular type of alloy as follows: Jq}o
0.2
=3.92, where q =9.81 m}s
2
is the
gravitational acceleration.
Fig. 9. Typical tensile stressstrain curve for 6060-T5 aluminium.
Fig. 10. Stressstrain curves for polyurethane foams of three dierent densities.
The variety of commercial tubes available was insucient to achieve the full range of D}t
values we required. To produce tubes with very large D}t ratios, the outside surface of stock
tubes was machined to produce the wall thickness desired. The nal thickness, mean diameter
and Vickers hardness were measured for each compression testpiece. Vickers hardness read-
ings were used to quantify the mechanical properties of each tube testpiece through the above
equation. A representative sample of these tube properties and the results of our testing may be
found in the appendix.
Most tests involved empty aluminium alloy tubes. However, some tests were carried out on
aluminium alloy tubes which had been lled with polyurethane foam. This polyurethane foam
usually comes as a two part mix (base and accelerator) and we used three dierent densities
(35, 60 and 140 kg}m
3
) during testing. Fig. 10 shows typical compressive stressstrain curves
for the three dierent density foams, which were obtained from axial compression tests on
96 mm diameter cylindrical foam blanks unrestrained laterally.
3. Experimental results and discussion
Our experimental results are summarised on the following pages in terms of the collapse
mode, average force F
AV
, force ratio F
MAX
}F
AV
, eccentricity factor m and the eect of foam
lling.
3.1. Collapse mode
Further examples of collapse modes are shown in Fig. 11, in addition to those shown in Fig.
2. Of particular interest was the non-symmetric mode (refer to Fig. 2b) which has multiple
corners (or lobes). We observed that for tubes with an increasing D}t ratio, the number of
Fig. 11. Further examples of collapse modes for axially loaded thin-walled 6060-T5 aluminium tubes:
(a) mixed mode (D = 57.1 mm, t = 1.15 mm, L = 628 mm); (b) three sided non-symmetric folding
(D = 57.1 mm, t = 1.15 mm, L = 628 mm); (c) Euler buckling (D = 58 mm, t = 2.0 mm, L = 566 mm).
Fig. 12. Schematic axial view of spiralling non-symmetric folding with N = 3
1
2
lobes, from Grzebieta [13].
Fig. 13. Mode classication chart for circular 6060-T5 aluminium tubes.
circumferential lobes also increased from 2 up to 5 or 6. At high values of D}t (200), the
number of lobes often varied during testing (in one case erratically between 3, 4 and 5 lobes).
The number of lobes, N, was not always an integerfor example, in some cases we observed
a relatively stable pattern with 3
1
2
lobes in a spiralling arrangement (refer to Fig. 12). In other
cases the lobes were simply incompletely formed.
From our test results for as-received 6060-T5 aluminium tubes a mode classication chart
was produced, see Fig. 13. This chart is divided up into areas which correspond, approximately,
to the dierent modes of collapse. The general shape of our chart is similar to that produced
by Andrews et al. [7], who tested annealed aluminium tubes. However, there are noticeable
dierences in the location of the lines delineating the various areas. For example, consider an
aluminium tube with D}t = 50 and L}D = 10. From our chart we would expect a mixed mode
Fig. 14. Plot of non-dimensional experimental average force F
AV
}M
P
versus D}t.
collapse but from Andrews et al. chart an Euler collapse is indicated. Note that a logarithmic
scale is used for D}t on our chart in order to cover the wider range of D}t values considered. It
may be observed broadly from our chart that non-symmetric mode is present when D}t 100,
while axi-symmetric mode occurs when D}t 50 and L}D2.
3.2. Average crush force
One of the most signicant parameters for quantifying the behaviour of axially compressed
tubes is the average crush force F
AV
. This is usually expressed non-dimensionally as a ratio
F
AV
}M
P
. When calculating the plastic moment, M
P
, dierent researchers have used various
dierent measures for the ow stress, o
0
. Since our tests involved only aluminium we chose to
take the value of 0.2% proof stress, o
0.2
, as the ow stress. Thus eectively:
M
P
=o
0.2
(t
2
}4).
Fig. 14 shows our test results for non-dimensionalised average axial force, F
AV
}M
P
, plotted
logarithmically versus D}t. There is only a relatively small amount of experimental scatter (some
points shown represent more than one test result). Note that when calculating the average axial
force, F
AV
, results for the initial peak have been ignored. From Fig. 14 it can be seen that
when plotted logarithmically, all the results (whether axi-symmetric, non-symmetric or mixed
modes) approximately form a straight line. Hence, we obtained the following empirical relation
for 6060-T5 aluminium alloy tubes:
F
AV
M
P
= 72.3
D
t
0.32
. (8)
This equation is of similar form to Eq. (4) proposed by Abramowicz and Jones in 1984 [8]
for non-symmetric mode but quite dierent from the corresponding equation proposed by Gupta
and Gupta [2].
Fig. 15. Comparison of present experimental results for average crush force with empirical equations of Gupta and
Gupta [2].
3.3. Comparison of experiment and theory for average force
The following paragraphs are a subjective comparison between our experimental results for
average crush force, F
AV
, and various theories and empirical relationships.
Fig. 15 shows our test results for F
AV
compared with empirical equations by Gupta and Gupta
[2]. They used Vickers hardness, J, to characterise material properties. These equations were
determined from tests on metal tubes with a relatively small range of dimensions (D}t =1033,
L}D = 23). In view of this, agreement for both axi-symmetric and non-symmetric modes is
quite good in the range D}t = 10100. For D}t 100, their curve for axi-symmetric mode is
closer to our experimental test points than their non-symmetric one, even though the actual
collapse mode exhibited was non-symmetric.
Fig. 16 shows our test results for average force, compared with equations developed by
Abramowicz and Jones [8]. From this gure it may be seen that agreement for both axi-symmetric
and non-symmetric modes is fair. Their axi-symmetric equation predicts average forces which are
rather low compared with our test points. On the other hand, their equation for non-symmetric
mode, Eq. (4), predicts average forces which are rather high compared with our test points.
Nevertheless, it may be noted from Fig. 16 that the slope of the line representing Eq. (4)
(non-symmetric mode) is almost the same as our test points. This is also evident from a
comparison of Eqs. (4) and (8).
Fig. 17 shows our test results for average force, F
AV
, compared with the theoretical equations
developed by Abramowicz and Jones [9]. Their axi-symmetric Eq. (3) estimates an average
force which is still low compared with our test results, but closer to our test points than their
1984 prediction. In the case of non-symmetric collapse, Abramowicz and Jones [9] developed
Eq. (5), which produces a family of lines, one for each value of N. Thus, we need to know the
number of lobes, N, in order to interpret Fig. 17. From the appendix it will be noted that for
most of the tubes we tested, N falls in the range N =34. Agreement between their theory and
Fig. 16. Comparison of present experimental results for average force with theory by Abramowicz and Jones [8].
Fig. 17. Comparison of present experimental results for average force with theory by Abramowicz and Jones [9].
our test points is good in this range. For cases with low D}t values (50), where N 3, their
prediction for F
AV
is rather low. For high values of D}t (300), where N 4, their predicted
value for F
AV
is rather high. Nevertheless, overall it appears that this method of predicting F
AV
is satisfactory.
Fig. 18 shows our test results for average force compared with the equations developed by
Singace et al. [17,18]. Their equation for axi-symmetric mode, Eq. (6), gives values for F
AV
which are much too low compared with our test points. In the case of non-symmetric mode,
their Eq. (7), when plotted on logarithmic axes produces a series of very steep lines, one for
each number of lobes, N. This makes the process of interpretation even more dicult.
Determining the precise number of corners or lobes for each test specimen presents some
practical diculties. As has previously been noted, if D}t 200 we sometimes observed that
Fig. 18. Comparison of present experimental results for average force with theory by Singace et al. papers [1618].
the number of lobes varied during the one test. Nevertheless, on Fig. 18 test points are shown
for which we felt condent of the lobe number. It will be noted that the lines representing the
Singace et al. Eq. (7) are not inconsistent with our test points although agreement is not close.
However, we observed that when the number of lobes varied during testing there was not a
corresponding variation in the instantaneous crush force. This observation casts doubt on the
validity of Eq. (7), as the large gaps between the lines in Fig. 18 suggest there should be a
large variation in crush force with a change in the number of lobes, N.
3.4. Discussion of average force
At this stage the following observations may be made. In general, the existing theories produce
numerical predictions for average force which are reasonable only for a limited range of D}t.
Comparison of our test results with these theories has revealed two fundamental features which
remain inexplicable at present. The rst feature is that all our test points, regardless of mode
of collapse (axi-symmetric or non-symmetric), lie on one curve whereas the theories treat these
modes quite separately. Further, most theories for non-symmetric mode predict average forces
which are a function of the number of lobes but experimentally this does not appear to be the
case.
The second, more important, feature relates to the functional dependence of average force on
D}t. Our experiments clearly show that F
AV
}M
P
is empirically dependent on (D}t)
0.32
. Existing
theories for axi-symmetric mode, however, suggest that F
AV
}M
P
should be dependent on

D}t.
In the case of non-symmetric mode, a wide variety of theories have been suggested; typically
F
AV
}M
P
is seen as being a linear function of D}t as for the Singace et al. Eq. (7). An exception
to this is Eq. (4) developed by Abramowicz and Jones [9], where F
AV
}M
P
was proportional
to (D}t)
0.33
. However, as previously noted, this equation appears to have developed from work
by Wierzbicki and Abramowicz [10] on rectangular rather than circular tubes. Thus it seems
Fig. 19. F
MAX
}F
AV
force ratio versus D}t.
that for circular tubes a rigorous theoretical explanation of the D}t exponent of
1
3
is still to be
developed.
3.5. Force ratio F
MAX
}F
AV
In a previous paper, Guillow and Lu [23] identied the force ratio F
MAX
}F
AV
as being of
some interest. In that paper it was noted that F
MAX
}F
AV
varied as a function of D}t ratio (this
has also been noted by other researchers). The variation in force ratio highlights the fact that
the mechanics of formation of the initial and subsequent folds is substantially dierent. Fig. 19
shows the results of our more recent tests at larger values of D}t. The F
MAX
}F
AV
ratio appears
to be monotonically increasing up to D}t = 450. Variability in the F
MAX
}F
AV
ratio increased
markedly for D}t 100. This scatter could be due to signicant variation in the initial buckling
force, F
MAX
, at large values of D}t.
Incidently, the common wisdom attributes the scatter of initial buckling force to imperfection
sensitivity of thin-walled shells. However, Calladine [24] has recently provided an alternative
explanation based on post-buckling considerations.
3.6. Eccentricity factor m
When folds occur during progressive buckling, they form partly on the outside and partly
on the inside of the original tube prole. As previously noted, Singace et al. [1618] have
investigated this phenomenon by considering the eccentricity factor, m, (refer to Fig. 7 for its
denition). We were surprised at their claim that the factor m was approximately constant at
0.65. Therefore, we decided to examine our test pieces to see if the Singace et al. ndings
also applied to 6060-T5 aluminium alloy tubes. Our test results for axi-symmetric mode folding
are shown in Fig. 20. They appear to conrm that a constant value of approximately 0.65 also
applies in this case. (It is not clear why the m value should be so dierent at D}t = 20.)
Fig. 20. Eccentricity, m, as a function of D}t, for axi-symmetric mode.
Fig. 21. Eect of varying density of foam lling in 6060-T5 aluminium tubes. All tubes of length 196 mm, average
diameter 97 mm and thickness 1.0 mm. Refer to Fig. 10 for stressstrain curves of polyurethane foam.
3.7. Eect of foam lling
Most of our tests involved empty aluminium alloy tubes. However, a few tests were carried
out on aluminium alloy tubes which had been lled with polyurethane foam. Fig. 21 shows
some of our test results for foam-lled aluminium tubes and Table 1 presents the data for aver-
age axial crush force. Stressstrain curves for foam only were presented earlier in Fig. 10. All
of the aluminium alloy tubes used in this stage of testing were identical (D=97 mm, t =1.0 mm
and L = 196 mm). Test results for an identical empty aluminium tube are shown in Fig. 1.
We expected to observe an increase in the average crushing force, F
AV
, for aluminium alloy
tubes which had been lled with foam, as compared with identical empty aluminium tubes. In
fact, there is a complex interaction between the metal tubes and the foam lling. The foam
provides support for the thin walls of the aluminium tubes leading to an increase in the overall
Table 1
Comparison of average crush force for foam only, empty aluminium tubes and foam lled aluminium tubes
a
Foam density F
AV
for F
AV
for empty Sum of two F
AV
for foam
(kg}m
3
) foam only aluminium tube columns at lled A1
(kN) (kN) left (kN) tubes (kN)
35 0.908 15.53 16.44 19.32
60 2.685 15.53 18.22 21.10
140 12.43 15.53 27.96 28.45
a
Note that average force was calculated over 126 mm stroke under identical conditions for 6060-T5 aluminium
alloy tubes, L = 196 mm, D = 97 mm and t = 1.0 mm.
crushing force. Less obvious is the stiening eect the aluminium tube provides by preventing
lateral expansion of the foam when compressed. Table 1 shows that the average crush force
for a foam lled aluminium tube is about 10% greater than the sum of the average force for
an identical aluminium tube and foam cylinder blank tested separately. This point was noted
previously by Reddy and Wall [22].
Foam lling of thin-walled tubes has previously been observed to aect the mode of collapse.
A change in mode was demonstrated by the test cases considered. The collapse mode of an
empty aluminium tube was non-symmetric (refer to Fig. 2(b)) and the same applied to an
identical tube lled with foam of density 35 kg}m
3
. However, lling with polyurethane foam
of 60 kg}m
3
forced the lled aluminium tube to collapse in a mixed mode and foam of density
140 kg}m
3
produced axi-symmetric mode collapse.
4. Conclusion
This paper details the results of axial compressive tests on thin-walled circular 6060 alu-
minium tubes which were in the as-received, heat treated T5 condition. The load was applied
quasi-statically and the range of tubes considered was D}t =10450 and L}D 610. A collapse
mode classication chart for 6060-T5 aluminium tubes is presented, see Fig. 13.
An empirical relationship between average force, F
AV
, and D}t ratio for this particular mate-
rial was developed, see Eq. (8). It was found that F
AV
}M
P
was proportional to (D}t)
0.32
and that
this equation could be applied to axi-symmetric, non-symmetric and mixed modes of collapse.
Also, it was observed that the force ratio F
MAX
}F
AV
increased over the range of D}t consid-
ered. Measurement of the eccentricity factor, m, for axi-symmetric folds indicates that a value
of 0.65 (as previously assumed) is appropriate for 6060-T5 aluminium. The eect of lling
aluminium tubes with polyurethane foam and the resulting change in collapse mode were also
examined.
Available literature on the axial compression behaviour of thin-walled tubes was reviewed
and comparisons made, in terms of the average force, between the theories and the present
experimental results. It was found that reasonable numerical agreement existed between our test
results and the work by Abramowicz and Jones (Eq. (3) for axi-symmetric mode and Eq. (4)
for non-symmetric mode). However, for circular tubes, a rigorous theoretical explanation of the
functional dependence of F
AV
}M
P
on (D}t)
0.32
for all modes of collapse, as observed in our
experiment, needs to be developed.
Acknowledgements
The authors wish to thank the Australian Research Council for their nancial support of this
research and ORICA Chemicals for their assistance with polyurethane foam.
Appendix
Table A1
Sample compression test results for empty aluminium tubes
TEST D}t L}D Dimensions Collapse No. of J(kg o
0.2
F
MAX
F
AV
F
AV
} F
MAX
No. D t (mm) mode lobes }mm
2
(MPa) (kN) (kN) M
P
}F
AV
4 51.5 2.0 97.9 1.9 Axi-sym. 79 198 109 43.0 241 2.53
6 97 2.1 97 1.0 Non-sym. 3.5 79 198 56.6 15.4 311 3.68
8 97 3.6 97 1.0 Mixed 3 79 198 57.5 15.8 319 3.64
9 A 97 3.6 97 1.0 Non-sym. 3.5 79 198 54.5 16.25 328 3.35
10 A 51.5 2.1 97.9 1.9 Mixed 4 79 198 117.5 44.0 246 2.67
13 A 65 3.6 97.5 1.5 Mixed 3 79 198 87.5 30.18 271 2.90
16 A 172 2.0 96.6 0.56 Non-sym. 4 79 198 22.1 5.75 370 3.84
24 A 97 2.0 97 1.0 Non-sym. 3.5 79 198 58.6 15.72 318 3.73
33 179 4.0 96.5 0.54 Non-sym. 3.5 79 198 25.35 5.06 351 5.0
44 370 2.1 96.3 0.26 Non-sym. 5.5 79 198 5.55 1.66 496 3.34
54 D 430 2.0 96.2 0.22 Non-sym. 5 75 188 6.0 1.10 466 5.46
55 D 308 4.0 96.3 0.31 Non-sym. 4 68.3 171 10.64 1.84 439 5.77
56 D 331 2.0 96.3 0.29 Non-sym. 4.5 72.2 181 9.33 1.825 476 5.11
58 D 307 6.0 96.3 0.31 Non-sym. 4.5 76.6 192 10.63 2.00 423 5.32
59 D 186 7.1 96.5 0.52 Non-sym. 3.5 75 188 21.4 5.06 400 4.23
60 D 97.7 7.2 97 0.99 Other-non- Indet. 84.2 211 44.0 15.0 290 2.93
Sym +Euler
61 X 35.8 6.2 48.4 1.35 Mixed 2 71 178 37.7 18.7 231 2.02
67 F 9.84 1.24 29 2.95 Other-1 ax 78.3 196 70.9
Fold +comp
69 F 9.85 3.75 29 2.95 Other-non- 78.4 196 70.6
Sym +Euler
70 X 35.9 0.62 48.4 1.35 Axi-sym. 71 178 37.85 17.5 216 2.16
72 X 35.8 2.06 48.4 1.35 Mixed 2.5 71 178 36.5 19.0 234 1.92
73 X 35.8 4.13 48.4 1.35 Mixed 2.5 70.2 176 37.6 18.5 231 2.03
74 X 35.8 1.45 48.3 1.35 Axi-sym. 72 180 38.0 18.75 228 2.03
75 G 19.1 2.49 30.4 1.59 Axi-sym. 79.5 199 35.9 24.0 191 1.50
79 F 9.85 1.75 29 2.95 Axi-sym. 80.4 201 70.8 63.1 144 1.12
86 H 30.2 2.0 57.9 1.92 Axi-sym. 71.5 179 66.5 36.9 224 1.80
95 H 99 8.0 56.5 0.57 Non-sym. 3 82.2 206 16.65 4.50 269 3.70
96 H 49.6 11.0 57.1 1.15 Mixed 3 75.4 189 37.6 15.33 245 2.45
97 H 49.7 13.0 57.1 1.15 Non-sym. 3 75.4 189 37.0 15.1 242 2.45
98 H 182 8.0 56.1 0.31 Non-sym. 3.5 76.6 192 6.81 1.64 358 4.15
99 H 307 8.0 56.2 0.18 Non-sym. 4 75.4 189 0.625 395
105 D 439 4.0 96.2 0.22 Non-sym. 5 70 176 4.0 1.07 507 3.74
References
[1] Reid SR. Plastic deformation mechanisms in axially compressed metal tubes used as impact energy absorbers.
International Journal of Mechanical Sciences 1993;35:103552.
[2] Gupta NK, Gupta SK. Eect of annealing, size and cutouts on axial collapse behaviour of circular tubes.
International Journal of Mechanical Sciences 1993;35:597613.
[3] Alexander JM. An approximate analysis of collapse of thin-walled cylindrical shells under axial loading.
Quartely Journal of Mechanical and Applied Mathematics 1960;13:105.
[4] Pugsley A, Macaulay M. The large scale crumpling of thin cylindrical columns. Quartely Journal of Mechanical
and Applied Mathematics 1960;13:19.
[5] Johnson W, Soden PD, Al-Hassani STS. Inextensional collapse of thin-walled tubes under axial compression.
Journal of Strain Analysis 1977;12:31730.
[6] Magee CL and Thornton PH. Design considerations in energy absorption by structural collapse. SAE Paper
780434, 1978.
[7] Andrews KRF, England GL, Ghani E. Classication of the axial collapse of circular tubes under quasi-static
loading. International Journal of Mechanical Sciences 1983;25:68796.
[8] Abramowicz W, Jones N. Dynamic axial crushing of circular tubes. International Journal of Impact Engineering
1984;2:26381.
[9] Abramowicz W, Jones N. Dynamic progressive buckling of circular and square tubes. International Journal of
Impact Engineering 1986;4:24369.
[10] Wierzbicki T, Abramowicz W. On the crushing mechanics of thin-walled structures. Journal of Applied
Mechanics 1983;50:72734.
[11] Abramowicz W, Jones N. Transition from initial global bending to progressive buckling of tubes loaded
statically and dynamically. International Journal of Impact Engineering 1997;19:41537.
[12] Grzebieta RH. An alternative method for determining the behaviour of round stocky tubes subjected to axial
crush loads. Thin-Walled Structures 1990;9:6689.
[13] Grzebieta RH. On the equilibrium approach for predicting the crush response of thin-walled mild steel tubes.
PhD thesis, Department of Civil Engineering, Monash University, 1990.
[14] Grzebieta RH, Research into failure mechanisms of some thin-walled round tubes. In: Gupta NK, editor.
Plasticity and Impact MechanicsProceedings of IMPLAST96. New Delhi: New Age International Publishers,
1996. p. 30924.
[15] Wierzbicki T, Bhat SU, Abramowicz W, Brodkin D. Alexander revisiteda two folding element model of
progressive crushing of tubes. International Journal of Solids and Structures 1992;29:326988.
[16] Singace AA, Elsobky H, Reddy TY. On the eccentricity factor in the progressive crushing of tubes.
International Journal of Solids and Structures 1995;32:3589602.
[17] Singace AA, Elsobky H. Further experimental investigation on the eccentricity factor in the progressive
crushing of tubes. International Journal of Solids and Structures 1996;33:351738.
[18] Singace AA. Axial crushing analysis of tubes deforming in the multi-lobe mode. International Journal of
Mechanical Sciences 1999;41:86590.
[19] Thornton PH. Energy absorptions by foam lled structures. SAE Paper 800372, 1980.
[20] Lampinen BH, Jeryan RA. Eectiveness of polyurethane foam in energy absorbing structures. SAE Paper
820494, 1982.
[21] Reid SR, Reddy TY, Gray MD. Static and dynamic axial crushing of foam-lled sheet metal tubes. International
Journal of Mechanical Sciences 1986;28:295322.
[22] Reddy TY, Wall RJ. Axial compression of foam-lled thin-walled circular tubes. International Journal of
Impact Engineering 1988;7:15166.
[23] Guillow SR, Lu G. Quasi-static axial compression of thin-walled circular metal tubes including eects of
foam lling. In: Shanmugan NE, Liew JY Richard, Thevendran V, editors. Thin-walled structures: research
and development; Proceedings of the Second International Conference on Thin-Walled Structures, Singapore,
1998. Amsterdam: Elsevier, 1998. p. 7718.
[24] Calladine CR. A shell buckling paradox resolved. In: Durban D, Givoli D, Simons JG, editors. Advances in
the mechanics of plates and shells. Dordrecht: Kluwer Academic Publishers, in press.

Quasi-Static Axial Compression of Thi-Walled Circular Aluminium Tubes

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Quasi-Static Axial Compression of Thi-Walled Circular Aluminium Tubes

Uploaded by

Copyright:

Available Formats

International Journal of Mechanical Sciences 43 (2001) 21032123

Quasi-static axial compression of thin-walled

Corresponding author. Fax: +61-3-9214-8264.

You might also like