The combination of metals and carbon fiber reinforced polymer (CFRP) composites to fabricate thin-walled tubes has excellent energy absorption potential. Introducing origami patterns and filling with polyurethane foam can affect the deformation process of the composite tube, significantly improving its energy absorption performance. This study investigates the energy absorption characteristics of CFRP/metal composite origami thin-walled filled components under quasi-static axial loads through experiments and numerical simulations. First, the energy absorption performance of metal thin-walled tubes and composite thin-walled tubes is analyzed, and the effect of foam filling on their energy absorption performance is examined. It is found that CFRP/metal composite tubes exhibit significant improvement in energy absorption compared to individual metal or CFRP tubes. Additionally, the incorporation of origami patterns and polyurethane foam enhances the deformation stability of the composite tube and improves its energy absorption characteristics. Subsequently, the effects of design parameters, such as the fiber winding angle of the CFRP tube, the ratio of axial (10°) to circumferential (90°) winding angles, the dihedral angle of the metal tube pattern, and the number of pattern layers, on the energy absorption characteristics of the composite tube are studied in detail. The results show that with an increase in fiber winding angle and the ratio of axial (10°) to circumferential (90°) winding angles, the load fluctuations of the composite tube decrease, and stable progressive fracture deformation occurs, improving the energy absorption characteristics. When the dihedral angle of the metal tube origami pattern is 150° and the number of layers is 5, the composite energy absorption effect is optimal.
FilippoGDarioFGiovanniB, et al.Injury criteria for vehicle safety assessment: a review with a focus using human body models. Vehicles2022; 4(4): 1080–1095.
2.
ZhuMJShengGYQianWH, et al.Energy absorption characteristics of multi-cell tubes with different cross-sectional shapes under quasi-static axial crushing. Int J Crashworthiness2022; 27(2): 565–580.
3.
ZhangZYSunWZhaoYS, et al.Crashworthiness of different composite tubes by experiments and simulations. Composites Part B2018; 143: 86–95.
4.
WangZZhaoZHChenYS, et al.Structure design of aluminum/CFRP hybrid stringers accounting for multiple impact angles. Compos Struct2023; 305: 116554.
5.
YangHYRenYR. Crashworthiness design of CFRP/AL hybrid circular tube under lateral crushing. Thin-Walled Struct2023; 186: 110669.
6.
QinXYMaQHGanXH, et al.Failure analysis and multi-objective optimization of crashworthiness of variable thickness Al-CFRP hybrid tubes under multiple loading conditions. Thin-Walled Struct2023; 184: 110452.
7.
WangZJinXHLiQ, et al.On crashworthiness design of hybrid metalcomposite structures. Int J Mech Sci2020; 171: 105380.
8.
WuXYSunBZWangBZ, et al.X-ray microtomography analysis of the damage mechanisms in 3D circular braided carbon fiber/epoxy resin composite tubes under axial impact compression. Compos Commun2023; 41: 101650.
9.
ZhangFKLinYWuJA, et al.Comparison of stacking sequence on the low-velocity impact failure mechanisms and energy dissipation characteristics of CFRP/Al hybrid laminates. Polym Compos2022; 43(8): 5544–5562.
10.
CetinEBaykasoğluAErdinME, et al.Experimental investigation of the axial crushing behavior of aluminum/CFRP hybrid tubes with circular-hole triggering mechanism. Thin-Walled Struct2023; 182: 110321.
11.
YangCXChenZFYaoSG, et al.Quasi-static and low-velocity axial crushing of polyurethane foam-filled aluminium/CFRP composite tubes: an experimental study. Compos Struct2022; 299: 116083.
12.
LiXYYangHYLeiHS, et al.Lateral crashworthiness performance of CFRP/aluminum circular tubes with mesoscopic hybrid design. Compos B Eng2023; 251: 110489.
13.
YuHYShiHRChenSJ. A novel multi-cell CFRP/AA6061 hybrid tube and its structural multiobjective optimization. Compos Struct2019; 209: 579–589.
14.
ZhangJYLuBQZhengDF, et al.Experimental and numerical study on energy absorption performance of CFRP/aluminum hybrid square tubes under axial loading. Thin-Walled Struct2020; 155: 106948.
15.
MansorMAAhmadZAbdullahMR. Crashworthiness capability of thin-walled fibre metal laminate tubes under axial crushing. Eng Struct2022; 252: 113660.
16.
ShenYWuZYHuXD. Effect of reinforcement layer number on energy absorption of aluminum-CFRP hybrid square tubes under axial loading: experimental and numerical study. Thin-Walled Struct2020; 155: 106935.
17.
ZhaYBMaQHGanXH, et al.Deformation and energy absorption characters of Al‐CFRP hybrid tubes under quasi‐static radial compression. Polym Compos2020; 41(11): 4602–4618.
18.
SunGYWangZHongJY, et al.Experimental investigation of the quasi-static axial crushing behavior of filament-wound CFRP and aluminum/CFRP hybrid tubes. Compos Struct2018; 194: 208–225.
19.
MaJYChaiSBChenY. Geometric design, deformation mode, and energy absorption of patterned thin-walled structures. Mech Mater2022; 168: 104269.
20.
ZhouCHTengCHLuWL, et al.Crashworthiness design for novel polygonal asymmetric origami tubes. Thin-Walled Struct2024; 205: 112404.
21.
HeJFWenGLZhaoSY, et al.Energy absorption of graded thin-walled origami tubes. Int J Mech Sci2024; 282: 109609.
22.
WangBZhouCH. The imperfection-sensitivity of origami crash boxes. Int J Mech Sci2017; 121: 58–66.
23.
YasudaHYeinTTachiT, et al.Folding behaviour of Tachi–Miura polyhedron bellows. Proceedings of the royal society A: mathematical. Proc Math Phys Eng Sci2013; 469(2159): 20130351.
24.
SongJChenYLuGX. Axial crushing of thin-walled structures with origami patterns. Thin-Walled Struct2012; 54: 65–71.
25.
MaJYYouZ. Energy absorption of thin-walled square tubes with a prefolded origami pattern—part I: geometry and numerical simulation. J Appl Mech2014; 81(1): 011003.
26.
YangKXuSQShenJH, et al.Energy absorption of thin-walled tubes with pre-folded origami patterns: numerical simulation and experimental verification. Thin-Walled Struct2016; 103: 33–44.
27.
ZhangXChengGDYouZ, et al.Energy absorption of axially compressed thin-walled square tubes with patterns. Thin-Walled Struct2007; 45(9): 737–746.
28.
O’NeilJSalviatoMKimE, et al.Geometric effects on the crashworthiness of composite Kresling origami tubes. Int J Solid Struct2024: 113199.
29.
SongZBMingSZDuKF, et al.Energy absorption of metal-composite hybrid tubes with a diamond origami pattern. Thin-Walled Struct2022; 180: 109824.
30.
O’NeilJSalviatoMYangJ. Energy absorption behavior of filament wound CFRP origami tubes pre-folded in Kresling pattern. Compos Struct2023; 304: 116376.
31.
GharehbaghiHJamshidiMAlmomaniA. Experimental and numerical investigation of energy absorption in honeycomb structures based on lozenge grid unit cells under various loading angles. Composites Part C: Open Access2024; 15: 100546.
32.
LiSFGuoXLiaoJP, et al.Crushing analysis and design optimization for foam-filled aluminum/CFRP hybrid tube against transverse impact. Compos B Eng2020; 196: 108029.
33.
LiSHouYLHuangJ, et al.Exploring the enhanced energy-absorption performance of hybrid polyurethane (PU)-foam-filled lattice metamaterials. Int J Impact Eng2024; 193: 105058.
34.
WangHXieSCJingKK, et al.Closed-cell polyurethane in-situ foaming honeycomb for enhanced energy absorption and water intrusion resistance. Alex Eng J2025; 114: 572–587.
35.
SunYGDengYDengYF. Low-velocity impact failure of foam-filled GFRP trapezoidal corrugated sandwich structures. Eng Fract Mech2024; 298: 109952.
36.
GanNFFengYNYinHF, et al.Quasi-static axial crushing experiment study of foam-filled CFRP and aluminum alloy thin-walled structures. Compos Struct2016; 157: 303–319.
37.
PalaniveluSPaepegemWVDegrieckJ, et al.Crushing and energy absorption performance of different geometrical shapes of small-scale glass/polyester composite tubes under quasi-static loading conditions. Compos Struct2010; 93(2): 992–1007.
38.
LiZBChenRLuFY. Comparative analysis of crashworthiness of empty and foam-filled thin-walled tubes. Thin-Walled Struct2018; 124: 343–349.
39.
LiXHYinYZhuX, et al.Performance of hollow and aluminum foam-filled multi-cell thin-walled aluminum alloy tubes (6063-T5) under axial impact. Structures2023; 47: 1803–1821.
40.
WangYXLiMHZongZH, et al. Experimental investigation on the crashworthy performance of polyurethane foam-filled aluminum cans under repeated impact loads. Mech Adv Mater Struct. 2024; 1–16.
41.
FangJGSunGYQiuN, et al.On design optimization for structural crashworthiness and its state of the art. Struct Multidiscip Optim2017; 55: 1091–1119.
WangBXiongJWangXJ, et al.Energy absorption efficiency of carbon fiber reinforced polymer laminates under high velocity impact. Mater Des2013; 50: 140–148.
44.
TanWFalzonBGChiuLNS, et al.Predicting low velocity impact damage and Compression-After-Impact (CAI) behaviour of composite laminates. Compos Appl Sci Manuf2015; 71: 212–226.
45.
ZhouHJiangYYangGH, et al.The mechanical characteristics of an aluminum foam winding CFRP composite structure under axial compression. Heliyon2024; 10(11): e31658.
46.
UmbrelloDM’SaoubiROuteiroJC. The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel. Int J Mach Tool Manufact2007; 47(3-4): 462–470.
47.
WierzbickiTBhatSUAbramowiczW, et al.Alexander revisited—a two folding elements model of progressive crushing of tubes. Int J Solid Struct1992; 29(24): 3269–3288.
