Energy absorption of expansion tubes using a conical–cylindrical die: Experiments and numerical simulation

This paper is concerned with the plastic energy absorption behavior of expansion tubes under axial compression by a conical–cylindrical die. The experiments and numerical simulation using FEM are presented in this paper. Experiments were conducted on circular 5A06 aluminum tubes with an internal radius fixed at 22.5 mm and different thicknesses between 1 and 5 mm; the tubes were pressed axially onto a series of conical–cylindrical dies each with a different semi-angle from 5° to 20°, where the radius of the cylindrical part was 24 mm. A numerical analysis was performed to investigate the tube deformation and the friction between the tube and die. A good fit of the experimental data was obtained by taking the value of the friction coefficient μ=0.05. Based on these experimental and numerical results, characteristics of driving force–stroke curves in different deformation modes are discussed in detail. Effects of tube dimensions and semi-angle of the die on steady-state force and energy absorption efficiency are also presented. Based on these experimental studies, a theoretical analysis to explain the deformation mechanisms of the tube expanded by a die is carried out and will be given in a subsequent paper [1].