Lower-cost manufacturing methods have increased the anticipation for economical mass production of vehicles manufactured from composite materials. One of the potential applications of composite materials in vehicles is in energy-absorbing components such as hollow shells and struts (these components may be in the form of circular cylindrical shells, square and rectangular tubes, conical shells, and frusta). However, constructions which result in brittle fracture of the composite tubes in the form of circumferential or longitudinal corner crack propagation may lead to unstable collapse failure mode and concomitant very low energy absorption. As a result, metal-composite hollow tubes have been developed that combine the benefits of stable ductile collapse of the metal (which can absorb crushing energy in a controlled manner) and the high strength-to-weight ratio of the composites. The relative and absolute thicknesses of metal or FRP section has a substantial effect on energy absorption of the hybrid tubes. In particular, likelihood of delamination occurrence raises with increase in FRP thickness. This can reduce the energy absorption capability of the metal-FRP hybrid tubes. Additionally, adding a very thick FRP section may result in a global buckling failure mode (rather than local folding). Until now, there are no studies specifically addressing the effect of FRP thickness on energy absorption of hybrid tubes. In this study, the effects of fiber orientation and FRP thickness (the number of layers) on the energy absorption of S2-glass/epoxy-304 stainless steel square tubes were experimentally investigated. In addition, a new geometrical trigger was demonstrated which has positive effects on the collapse modes, delamination in the FRP, and the crush load efficiency of the hybrid tube. To complete this study, a new methodology including the combination of experimental results, numerical modeling, and a multi-objective optimization process was introduced to obtain the best combination of design variables for hybrid metal-composite tubes for crashworthiness applications. The experimental results for the S2 glass/epoxy-304 stainless steel square tubes with different configurations tested under quasi-static compression loading were used to validate numerical models implemented in LS-DYNA software. The models were able to capture progressive failure mechanisms of the hybrid tubes. In addition, the effects of the design variables on the energy absorption and failure modes of the hybrid tubes were explained. Subsequently, the results from the numerical models were used to obtain optimum crashworthiness functions. The load efficiency factor (the ratio of mean crushing load to maximum load) and ratio between the difference of mean crushing load of hybrid and metal tube and thickness of the FRP section were introduced as objective functions. To connect the variables and the functions, back-propagation artificial neural networks (ANN) were used. The Non-dominated Sorting Genetic Algorithm–II (NSGAII) was applied to the constructed ANNs to obtain optimal results. The results were presented in the form of Pareto frontiers to help designers choose optimized configurations based on their manufacturing limitations. Such restrictions may include, but are not limited to, cost (related to the number of layers), laminate architecture (fiber orientation and stacking sequence) which can be constrained by the manufacturing techniques (i.e. filament winding) and thickness (as an example of physical constraints). / Ph. D. / In a car accident, the incident energy must be absorbed by elements of the vehicles to prevent it from being transferred to the occupants. (Indeed, a vehicle that is not damaged in a crash may lead to significant injury to occupants.) Typical energy absorbing elements in a vehicle include hollow shells and struts in the crumple zone, bumpers, and airbags. The focus of this study is on hollow thin-walled tubes in the form of hybrid metal-composite square tubes which have the potential to provide cost-effective structures for energy absorption applications. The behavior of these elements is complicated, requiring computationally intensive and time-consuming computer simulations to analyze their failure and to improve their design. The time required for these simulations may lead to long times before new elements are introduced into the marketplace. Consequently, the objective of this study is to provide an efficient and fast methodology to obtain the best hybrid structures for crashworthiness applications. To support the computational modeling, experimental results obtained from the samples with different configurations tested under quasi-static compression loading were used to validate the models. The effect of fiber orientation, stacking sequence, and thickness of the composite on energy absorption and failure modes were predicted using the models. To reduce the time associated with computational modeling, artificial neural networks (ANNs) were employed to fit the response at selected training points and to generate a pool of responses at other points. These responses may then be used by a designer to choose the best solution for a set of competing design constraints.

This dissertation is concerned with a type of energy absorption device made of thin-walled tubes. The tubes will undergo plastic deformation when subjected to an impact loading, and therefore absorb kinetic energy. It has been found that, if the surface of a tube is pre-folded according to an origami pattern, the failure mode of the tube can be altered, leading to a noticeable increase in energy absorption while at the same time, reducing the force needed to initiate plastic deformation within the tube. The main work is presented in four parts. First of all, an experimental study of a type of previously reported thin-walled square tube with pre-manufactured pyramid patterns on the surface has been conducted. Quasi-static axial crushing tests show that the octagonal mode, although numerically proven to be efficient in terms of energy absorption, cannot be consistently triggered. Secondly, a new type of thin-walled tubular energy absorption device, known as the origami tube, which has origami pattern pre-fabricated on the surface, has been studied. A family of origami patterns has been designed for tubes with different profiles. The performances of a series of origami tubes with various configurations subjected to quasi-static axial crushing have been investigated numerically. It is found that a new failure mode, referred to as the complete diamond mode, can be triggered, and both over 50% increase in the mean crushing force and about 30% reduction in the peak force can be achieved in a single tube design in comparison with those of a conventional square tube with identical surface area and wall thickness. A theoretical study of the axial crushing of square origami tubes has been conducted and a mathematical formula has been derived to calculate the mean crushing force. Comparison between theoretical prediction and numerical results shows a good agreement. Quasi-static axial crushing experiments on several square origami tube samples have been carried out. The results show that the complete diamond mode is formed in the samples and both peak force reduction and mean crushing force increase are attained. Thirdly, a new type of curved thin-walled beam with pre-manufactured origami pattern on the surface, known as the origami beam, has been designed and analyzed. A numerical study of a series of origami beams with a variety of configurations subjected to quasi-static lateral bending has been conducted. The results show that two new failure modes, namely, the longitudinal folding mode and the mixed mode, can be induced, and both reduced peak force and increased energy absorption are achieved. Finally, a number of automobile frontal bumpers, which have the origami tube and the origami beam as key components, have been designed and analyzed. Three impact tests have been conducted on each bumper. The numerical results show that both types of origami structures can perform well in realistic loading scenarios, leading to improved energy absorption of the bumpers.

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