Paper Titles
Cylindricity Error by Least Square and Minimum Zone Fitting
p.149
Theoretical Foundations of Mechanical Design for Improving Machine Productivity during the Cutting Process
p.161
Tool Life Estimation and Optimization Using a Stacking Regressor and Whale Optimization Algorithm (WOA) in Micromilling
p.169
Research on the Wear of Cutting Inserts during the Processing of Waste Construction Glass
p.181
Failure Analysis of Thin-Walled Extruded Aluminum Tubes Using MSFLD-Based Criteria
p.193
Evaluation of Friction Coefficient During Single Point Incremental Forming of Commercial Purity Aluminium Alloy
p.205
Manufacturing Working Analysis of a Mechanical Wire Bending Machine
p.215
Development of a Time-Synchronised Micro-PMU System for Low-Voltage Grid Fault Prediction
p.229
Design and Development of a Modular Automated Pallet Changing System for CNC Machining Centres
p.237

Failure Analysis of Thin-Walled Extruded Aluminum Tubes Using MSFLD-Based Criteria

Article Preview

Abstract:

This study presents a numerical investigation of failure initiation and evolution in thin-walled extruded aluminum tubes subjected to three-point bending and dynamic axial compression. An explicit finite element framework is employed, combining the Müschenborn--Sonne forming limit diagram (MSFLD) with stress-state-dependent ductile and shear fracture criteria to capture multiple competing failure mechanisms. The approach accounts for instability-driven necking as well as fracture governed by evolving stress triaxiality and Lode parameter. Numerical predictions are validated against experimental results through both quantitative comparison of load-displacement responses and qualitative assessment of deformation patterns and fracture locations. The results demonstrate that incorporating stress-state-dependent fracture criteria significantly improves the predictive accuracy of crash simulations involving thin-walled aluminum structures.

You might also be interested in these eBooks
International Scientific Conference on Advances in Mechanical Engineering (11th ISCAME) View Preview

Info:

Periodical:

Advances in Science and Technology (Volume 181)

Pages:

193-203

DOI:

https://doi.org/10.4028/p-3VZv4p

Citation:

Cite this paper

Online since:

August 2026

Authors:

Attila Baksa*, Marwen Habbachi, Erika Baksáné Varga

Keywords:

Axial Load, Bending, Failure Test, FEM Solution, Thin-Walled Al Tube

Export:

RIS, BibTeX

Price:

Permissions CCC:

Request Permissions

Permissions PLS:

Request Permissions

Сopyright:

© 2026 Trans Tech Publications Ltd. All Rights Reserved

Share:

Citation:

* - Corresponding Author

References

[1] M.H.M. Hanid, S. Sharif, M. Ahmad, M. A. Suhaimi, C. Y. Khor, and K. A. Ismail. Crashworthiness performance of thin-walled structures towards design configuration in vehicle crash boxes application: a review. International Journal of Crashworthiness, 2025.

DOI: 10.1080/13588265.2025.2492975

Google Scholar

[2] A. Baroutaji, M. Sajjia, and AG. Olabi. On the crashworthiness performance of thin-walled energy absorbers: Recent advances and future developments. Thin-Walled Structures, 118:137– 163, 2017.

DOI: 10.1016/j.tws.2017.05.018

Google Scholar

[3] W. Abramowicz and N. Jones. Dynamic axial crushing of circular tubes. International Journal of Impact Engineering, 2:263–281, 1984.

DOI: 10.1016/0734-743x(84)90010-1

Google Scholar

[4] M. Langseth and O. S. Hopperstad. Static and dynamic axial crushing of square thin-walled aluminium extrusions. International Journal of Impact Engineering, 18(7–8):949–968, 1996.

DOI: 10.1016/s0734-743x(96)00025-5

Google Scholar

[5] Y. Bao and T. Wierzbicki. On fracture locus in the equivalent strain and stress triaxiality space. International Journal of Mechanical Sciences, 46:81–98, 2004.

DOI: 10.1016/j.ijmecsci.2004.02.006

Google Scholar

[6] D. Mohr and S. J. Marcadet. Micromechanically-motivated phenomenological hosford– coulomb model for predicting ductile fracture initiation at low stress triaxialities. International Journal of Solids and Structures, 67–68:40–55, 2015.

DOI: 10.1016/j.ijsolstr.2015.02.024

Google Scholar

[7] ABAQUS Ltd. online. Abaqus Example Problems Manual Volume I: Static and dynamic analyses., 2019. version 6.7.

Google Scholar

[8] W. Müschenborn and H. Sonne. Einfluß der formänderungsweges auf die grenzformänderungen des feinblechs. In Archiv für das Eisenhüttenwesen, volume 46, pages 597–602, 1975.

DOI: 10.1002/srin.197503686

Google Scholar

[9] D. Banabic. Sheet Metal Forming Processes: Constitutive Modelling and Numerical Simulation. Springer, 2010.

Google Scholar

[10] T. B. Stoughton and J. W. Yoon. Path independent forming limits in strain and stress spaces. International Journal of Solids and Structures, 49(25):3616–3625, 2012.

DOI: 10.1016/j.ijsolstr.2012.08.004

Google Scholar

[11] M. G. Cockcroft and D. J. Latham. Ductility and the workability of metals. Journal of the Institute of Metals, 96:33–39, 1968.

Google Scholar

[12] G. R. Johnson and W. H. Cook. Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Engineering Fracture Mechanics, 21(1):31–48, 1985.

Google Scholar

[13] Y. Bai and T. Wierzbicki. A new model of metal plasticity and fracture with pressure and lode dependence. International Journal of Plasticity, 24:1071–1096, 2008.

DOI: 10.1016/j.ijplas.2007.09.004

Google Scholar

[14] H. Hooputra, H. Gese, H. Dell, and H. Werner. A comprehensive failure model for crashworthiness simulation of aluminium extrusions. International Journal of Crashworthiness, 9:449–463, 2004.

DOI: 10.1533/ijcr.2004.0289

Google Scholar

[15] D. Gutiérrez, A. Lara, D. Casellas, and J. M. Prado. Effect of strain paths on formability evaluation of TRIP steels. Advanced Materials Research, 89-91:214–219, 2010. Trans Tech Publications, Ltd.

Google Scholar

[16] Kolasangiani K., Shariati M., and Farhangdoost K. Prediction of forming limit curves (FLD, MSFLD and FLSD) and necking time for SS304L sheet using finite element method and ductile fracture criteria. Journal of Computational and Applied Research in Mechanical Engineering, 4(2):121–132, 2015.

Google Scholar