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Experimental Study of Corrugated Tubes Under Lateral Loading

Article  in  Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications · April 2012
DOI: 10.1177/1464420712437307

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 Proceedings of the ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis
ESDA2010
July 12-14, 2010, Istanbul, Turkey
th
Proceeding of the 10 Biennial International Conference on Engineering Systems Design and Analysis
ESDA2010
July 12-14, 2010, Istanbul, Turkey

ESDA2010-
ESDA2010-24782

EXPERIMENTAL STUDY OF CORRUGATED TUBES UNDER LATERAL LOADING

A. Eyvazian M. Shakeri
M.Sc. Student, Mechanical Professor, Mechanical
Engineering Department, Engineering Department,
Amirkabir University of Amirkabir University of
Technology Technology
Tehran, Iran Tehran, Iran

M. Zarei Mahmoudabadi
M.Sc. Student, Mechanical
Engineering Department,
Amirkabir University of
Technology
Tehran, Iran

ABSTRACT be produced by this method. Experimental tests are conducted

The protection of structures under impact loading
often necessitates the need for energy absorbers; devices
designed to absorb the impact energy in a controlled manner
and hence, protect the structure under consideration. Thin-
walled tubes are widely used as energy absorbers in various
vehicles and moving parts. The objective of the present study
is to investigate the energy absorption characteristic of tubes
with corrugations in different geometries, in lateral direction.
In order to produce corrugations, an innovative solution is
introduced. Corrugations can be very easily generated on the
surface of cylindrical aluminum tubes by stamping method.
Corrugations with different wavelengths and amplitudes can
to study the effect of changing corrugation geometry (type and
amplitude). Quasi-static tests are carried out whose results for
lateral compression show that tubes with corrugation have a
higher mean crushing force and this force is directly
proportional to number of corrugations and their amplitude.
Moreover, it is observed that corrugated tubes can absorb
approximately four times more energy than tubes without
corrugations, in the same size and weight. Finally,
considering the experimental tests, corrugated tubes are shown
to be more effective in lateral direction as an energy absorber,
and they also exhibit desirable force-deflection responses
which are important in the design of energy absorbing devices.

KEYWORDS—Corrugated tube, Energy absorption,

Quasi-static loading, Deformation Mode, laterally crushing.

1. INTRODUCTION elements. When used specifically as energy absorbing

Aircrafts, ships, space vehicles, etc. have to withstand components, tubes are most often loaded either axially or
an accidental crash for which efficient energy absorbing laterally. A number of different deformation mechanisms can
devices are required. Various devices have been proposed and be produced by axial compression. Four these include
are in current use. axisymmetric (bellows) or asymmetric (diamond fold)
Thin metal tubes form a very important component in many of buckling, inversion (by compression die) or fracture (frangible
these devices because of their low cost, ready availability and tube). Although the energy absorbing capacity of these axial
energy absorbing efficiency (i.e. energy absorbed per unit compression modes is high, the devices have certain defects.
weight of the material used) compared with other deforming For example, the axial load on such cylindrical tubes is highly
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 non-uniform in character. Load-displacement curve of such
tubes shows that the axial force first reaches an initial peak
followed by a drop, and then fluctuates. Furthermore, all
systems with axially compressed tubes operate successfully,
only if the line of application of load is inclined at an angle
less than around 15° to the axis of the tube, and the maximum
possible safe stroke efficiency, i.e. the ratio of the reduction in
length to the undeformed length of the device, is only about
65%.
Tubes under lateral (radial) compression overcome some of
the above disadvantages. For example, their load displacement
curve for lateral loading is smooth, devices with laterally
loaded tubes are easier to build than most other devices, and
their efficiency is not affected by the direction through which
the load is applied.
Some researchers have investigated tubes with several design
features intended to improve energy absorption properties,
including periodic processed grooves [1] and performed waves
(corrugations) that run in the axial and radial directions [2-5].
Singace and El-Sobky [3] experimentally studied the effect of
introduction of corrugations on the load-displacement and
energy absorption characteristics of circular aluminum and
PVC tubes. Hydro-forming was used to form corrugation on
straight tubes. They found that corrugations or grooves could
control the energy absorption of the tube to some extent, and
improve the uniformity of load-displacement curve. However,
their investigation considers only corrugations with the same
geometry and the method to introduce the corrugations is not
economical in comparison with conventional tubes.
Experimental studies were carried out by Daneshi and
Hosseinpour [6] to investigate the effect of introducing
grooves to circular steel tubes under axial crushing.
Alternately, inside and outside annular groove patterns were
scratched on the tube surface. Their investigation showed
similar result. Lee Et Al. [7] and Mamalis Et Al. [8,9]
2. EXPERIMENTAL TEST PROGRAM
In this work, the quasi-static analysis of corrugated
circular energy absorbers under lateral loading is examined
using experimental techniques. Although these devices are
usually exposed to much higher velocities, it is common to
analyze the quasi-static response first, since the same pre-
dominant geometrical effects will also occur under dynamic
loading conditions.
2.1 Geometry
Six types of specimens are investigated. In order to
investigate the effect of corrugations on lateral response load,
there is difference in the number of corrugations and depths.
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conducted experimental tests and numerical simulations for
the effect of dents and axially compressed square and circular
tubes.
Lateral compression of single circular tubes has been analyzed
both experimentally and numerically by several researchers
[10,13] on lateral crushing of circular and non-circular tube
systems under quasi-static conditions. These authors were
among the first to analyze such problem, and each one of them
proposed a slightly different deformation mechanism for the
compression of a tube between rigid flat platens. Nested
systems of various configurations containing metallic tubes
have been analyzed. [14] The response of elliptical braced
tubes under lateral compression has been analyzed
theoretically, numerically and experimentally [15]. The
advantage of such absorbers is two folds in that the bracing
provides for a higher collapse load while the elliptical shaped
tubes allows for a greater displacement stroke to be obtained
than their circular counterparts.
After review of previous literature, it was found that
corrugations are all generated in same size. In order to obtain a
comprehensive understanding of lateral collapse characteristic
of circular cylinders with periodic corrugations, it is essential
to conduct investigations on the effects of corrugations
geometry.
Unfortunately, the ability to generate the energy absorption
data for metallic corrugated tube, especially experimental
tests, is still scarce and up to author’s knowledge, only few are
available in the literature. In this paper, a comprehensive
experimental work is performed to study the response of
aluminum corrugated tubes to quasi-static compressive
loading in lateral direction.
Moreover, inner and outer corrugations are also considered.
Corrugation producing method gives the flexibility to have a
combination of corrugations. All specimens are cut from one
continuous tube and machined in both ends precisely.
Specimens have the same thickness and the value of wall
thickness is 2.5 mm, and they have the same diameter of 79.5
mm. The elective length of the test specimens is 70 mm.
Details on specimens’ geometry for lateral compression are
given in table 1.
Figure 1 illustrates the six different specimens provided. S
type is a tube without corrugation. CID1 and CID2 are
provided to investigate the effect of corrugation number on the
energy absorption characteristic. In order to study the effect of
corrugation amplitude and difference in the inner and outer
corrugations, sample CIS2 and COD2 are prepared
respectively. Finally, due to method were used to the
corrugation production method, CIO3 specimens which have
both inner and outer corrugations are produced.
 Figure 1. TYPES OF TESTED SPECIMENS a) S, b) CID1, c) CID2, d) CIS2 e) COD2, f) CIO3

Table 1. TESTED SPECIMENS GEOMETRY

Corrugation Number of
wall Thickness Diameter Type of
Type amplitude corrugations
(mm) (mm) corrugation

S 2.5 79.5 - - -
CID1 2.5 79.5 3.9 1 Inner
CID2 2.5 79.5 3.9 2 Inner
CIS2 2.5 79.5 1.9 2 Inner
COD2 2.5 79.5 3.9 2 Outer
CIO3 2.5 79.5 4 3 Inner + Outer

2.2 Material property

The corrugated tubes are made up of an aluminum alloy.

The material properties are obtained by tensile testing of the
extrusion wall material parallel to the direction of the tube
axis. Representative engineering stress-strain curves of all
tested extrusions are given in Figure 2.

Figure 2. REPRESENTATIVE ENGINEERING STRESS-STRAIN

CURVES OF TESTED TUBES.
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 2.3 Preparation of test specimens
Seamless aluminum alloy (AA 6060) tubes, of 79.5 mm
nominal diameter and 2.5 mm thickness are selected, because
of their forming characteristics when compared to other
materials like mild steel. Also, they are affordable and easily
obtainable. Straight tubes are cut precisely and the ends of the
tubes are carefully machined in order to obtain flat and
parallel ends normal to the longitudinal axis.
Corrugations are fabricated by stamping method. In this
method, corrugations with different geometries are easily
made on the surface of straight aluminum tube. Dies used for
this process are made from steel and have two separate parts
which are opposite to each other. Special machinery is
designed to produce different types of corrugations. Dies are
installed on this machinery and are rotated in parallel manner,
but in inverse direction by means of a special mechanism.
Tubes are griped between two dies and during rotation, two
opposite dies become closer to each other gradually. In this
method, corrugations with different amplitudes can be
provided by choosing different distances between opposite
dies. Also, variation of corrugation length can be produced by
different dies. This method of producing corrugation has
advantages in comparison with hydro forming method. Firstly,
in this method, there is no need for expensive dies designed to
resist pressure, it significantly reduces the cost of producing
corrugated energy absorber. Moreover, this method is very
flexible and corrugations can be fabricated on the tubes with
different wall thicknesses and diameters. Figure 3 shows a
corrugated tube and the die assembly.
3 RESULTS AND DISCUSSION
Since the responses of corrugated tubes in lateral
compression are different and have their own force-
displacement curves, and various failure modes are observed
for each one, failure mode and energy absorption parameters
are discussed independently.
3.1 Failure mode
Corrugated tubes are crushed in two different modes under
lateral loading. The first mode happens in simple tubes
without corrugations, CIS2 and COD2. In this mode, in the
first part of the curve, the radial load increases sharply, due to
elastic changes, and two longitudinal hinges are observed to
have developed. After this stage, the tube begins to yield and
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Figure 3. STAMPING METHOD FOR FABRICATION OF
CORRUGATIONS
2.4 Testing procedure
Different quasi-static tests are performed on corrugated
tubes in order to study the behavior of such tubes when
subjected to lateral crushing. In each case, the load
displacement curve is produced.
The specimens are tested in quasi-static lateral loading
between two dies which fix two ends of the tubes. (Figure 4)
Instron digital testing machine with full scale load of 500 kN
is used. Load platens are set parallel to each other before
testing. To stimulate quasi-static conditions and to ensure no
dynamic effect is present, all tubes are compressed at a rate of
5 mm/min until limited crash, which implies complete
compaction of tested tube and load recorded increases sharply.
Loads and displacements are recorded by automatic data
acquisition system.
two hinges are formed diametrically opposite to each other at
180° angles as seen in Figure 4. Furthermore, it can be seen
that this part of the load response becomes approximately
linear. This stage continues as deformation proceeds up to the
full crushing of the tube. In the final stage, load response rises
up sharply which indicates the end of crushing zone.
The second mode happens for tubes with corrugation. In this
mode, four longitudinal hinges appear on the tubes wall. These
hinges form diametrically at 90° angles as seen in for
specimens with higher amplitude, CID1, CID2 and CIO3
(Figure 4). Hinges which are located horizontally are formed
earlier than vertical hinges. Similar to the first mode, in this
mode we also have three stages on the load displacement
curve.
 S

CID1

CID2

CIS2

COD2

CIO3
Figure 4. DEFORMATION HISTORY OF DIFFERENT CORRUGATED TUBES UNDER LATERAL LOADING

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 3.2 Crushing energy absorption
Energy absorption capability can be compared by
knowing different parameters. These parameters are illustrated
in the following sections. Table 2 shows these parameters.
3.2.1 Total absorbed energy
Total absorbed energy is the area under load-displacement
curve. In this study, it is a function of corrugation number and
corrugation amplitude. This energy can be obtained by
numerical integration of the load-displacement curve. It is
found from experimental results that CIO3 with three
corrugations has the maximum total energy absorption. This
type of corrugated tube has a capacity to absorb 302% more
energy than tube without corrugation (Figure 7). All
experimental results show improvement in crashworthiness
characteristic of corrugated tubes. The comparison between
different specimens is illustrated in Figure 5 and Table 2.

Energy Absorbed
210
200
190
COD2
180
170 S
160
150 CID2
140
CIO3
130
120 CIS2
Energy (J)

110
100 CID1

90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80
Displacement (mm)

Figure 5. TOTAL ABSORBED ENERGY FOR DIFFERENT CORUGATED TUBES

Table 2. CRASHWORTHINESS PARAMETERS OF LATERAL TESTS FOR DIFFERENT CORUGATED TUBES

Stroke efficiency (%) Spc. Energy absorbed (Es)

Type Mean load (N) Total energy abs. (J)
(kJ/kg)

S 809.15 61.79 97.3 20.228

CID1 1863.63 121.55 87.5 46.591

CID2 2298.07 139.00 78.6 57.452

CIS2 1023.03 88.54 94.28 25.576

COD2 2408.91 156.64 90.65 60.222

CIO3 3256.91 202.77 78.6 81.422

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 3.2.2 Mean load different tubes mean crushing loads. As it is mentioned in the
Introduction, lateral crushing of tubes has the advantages of
Mean load is the average of crushing load response smooth load displacement diagram. Moreover, in the load
through complete deformation of the tube. It is useful to displacement characteristic, there is no initial peak load, which
measure the performance of an energy absorber and play an is usual in axial crushing of tubes and is very dangerous for
important role in energy absorbers design calculated as the system being protected from crush and it can cause great
E damages.

P
u
where E and u are the total absorbed energy and crush length
load, respectively. Figure 8 illustrates the comparison between

Load-displacement

7000
S

CIO3
6000
CID1

COD2
5000
CID2

CIS2
4000

Load (N)

3000

2000

1000

0
0 10 20 30 40 50 60 70
Displacement (mm)

Figure 6. LOAD DISPLACEMENT DIAGRAM FOR TESTED SPECIMENS

3.2.3 Stroke efficiency (SE)

Crushing of a tube leads to the compaction of the tube. 3.2.4 Specific energy absorption (Es)
This results in a continuously increasing load level as the
deformation increases. Practical use of the absorber beyond To compare different materials or different geometry
this limit would lead to load levels exceeding that is given as of specimens, it is necessary to consider the specific energy.
the maximum acceptable limit. The relative deformation of the The specific energy is defined as the amount of energy
absorber at which compaction takes place is referred to as the absorbed per unit mass crushed material. Therefore, the
SE of the absorber. The SE can be obtained as specific energy (Es) that is dependent on the structure
u geometry is mentioned here to compare aluminum corrugated
SE 
h tubes with other types of energy absorbers. Specific energy
where u and h represent the crush length and the diameter of absorption (Es) can be calculated as
the specimen. In this study, it is shown that for failure mode E
having two hinges, as obvious in Figure 4 stroke efficiency, is E 
Vρ
higher in comparison with the failure mode that has 4 hinges. where  is the total absorbed energy, V is the volume of the
Also, it is clear that higher stroke efficiency results in higher tube, and  is the density of the tube. Product of last two terms
energy absorption capacity.

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 is equal to the tube mass. High values of Es indicate the have higher mean crushing load and total energy absorption.
lightweight absorber. For comparison, deeper corrugation increases the mean
crushing load and total absorbed energy for 124% and 57%
250
respectively.
202.77
Effect of changing corrugation shape: in the experimental
200 test program, two specimens are provided to study how inner
156.64
139 corrugation differs from outer corrugation in the crush
150 121.55 response. CID2 and COD2 are fabricated by stamping method
88.54
through changing the die position. The comparison between
100 these two specimens by means of load displacement diagram
61.79
(Figure 6) and total absorbed energy diagram (Figure 5) shows
50 that there is no significant difference between these two types
of energy absorbers, and mean crushing load and total
0 absorbed energy for outer corrugation is only 4.5 % and
S CID1 CID2 CIS2 COD2 CIO3 12.7% higher than inner corrugation.
Type of tube Effect of combining inner and outer corrugation: specimen
Figure 7. TOTAL ABSORBED ENERGY OF THE SIX type CIO3 is provided in order to see how combining two
CORRUGATED TUBES SUBJECTED TO LATERAL LOADING types of corrugations will affect crashworthiness of corrugated
tubes. Experimental test results show that there is significant
increase in both mean crushing load and total absorbed
energy. In comparison with tubes without corrugation, mean
3500 3256.91
crushing load increases 302% and the total energy absorbed
3000 increases 228%.
2298.07 2408.91
2500 4 CONCLUSION
1863.63
2000
The objective of this paper is to experimentally study the
1500
1023.03 effect of corrugation on the crushing behavior and energy
809.15
1000 absorption of aluminum circular tubes. Circular corrugated
tubes are also prepared and tasted under the same conditions
500
in order to provide a means for comparison. Six types of
0 specimens are subjected to quasi-static lateral compression
S CID1 CID2 CIS2 COD2 CIO3 loads. Based on the result obtained, the main conclusion points
Type of tube can be summarized as follows:
Figure 8. MEAN CRUSHING LOAD OF SIX CORRUGATED a) Aluminum corrugated tubes exhibit an effective and
TUBES SUBJECTED TO LATERAL LOADING stable energy absorption phenomenon under lateral
compression.
3.3 Effect of corrugation
b) Fabricating corrugations on the tubes improves both
Corrugation has significant effects on the load caring capacity mean crushing load and total absorbed energy.
of axial crushing. Obviously, crushing load increases with c) Amplitude of corrugation plays an important role in the
specimens with corrugated circumstances. Different types of crashworthiness characteristic of this type of energy
corrugation which is investigated in this study are discussed in absorbers.
this section: d) Energy absorption parameters of corrugated tubes are
Effect of corrugation number: two specimens CID1 and relative to the failure mode, and four-hinge failure mode
CID2 are provided to study how the number of corrugation
provides a higher value of crashworthiness.
will affect the load response of this type of energy absorbers.
Based on the results obtained, both the total absorbed energy e) Tubes with inner and outer corrugations exhibit high
and mean crushing load are increased 23% and 14% when one energy absorption capacity under lateral loading.
more corrugation is fabricated on the tube.
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