Finite element simulations of the bending resistance of square profiles with topological modifications

Abstract

Bending resistance is one of the most important requirements in automobile structural members when lateral crashes occur. For this purpose, the current paper studies the bending and crashworthiness capacity of square profiles with topological modifications. Several finite element simulations were carried out using Abaqus/Explicit software. The topological modifications consisted in combining a square cross-section with polygonal and circular simple cross-sections. In all cases, the profiles evaluated were simulated with mechanical properties for aluminium alloy 6063-T5 with the same mass. The feasibility of our numerical study was validated by a three-point bending tests of a square tube using a Shimadzu universal test machine. Additional to the assessment of complex cross-sections, numerical results for simple cross-sections are presented. A better crashworthiness performance is obtained when the square section of a simple profile is reinforced with topological modifications. According to the simulation results, a complex cross-section can improve the crushing force efficiency up to 77.9% with respect to a single square profile. Regarding cross-sections with topological modifications, the best bending resistance and energy absorption capacity is obtained when the square section is combined with a square profile. This means an increase of 9.2 % of energy absorption (Ea) and 5.67% of CFE respect to the cross-section formed by square and triangular shapes.