Energy Absorption of All-Metallic Corrugated Sandwich Cylindrical Shells Subjected to Axial Compression

Abstract The energy adsorption properties of all-metallic corrugated sandwich cylindrical shells (CSCSs) subjected to axial compression loading were investigated by the method combining experiments, finite element (FE) simulations, and theoretical analysis. CSCS specimens manufactured using two different methods, i.e., high-speed wire-cut electric discharge machining (HSWEDM) and extrusion, were tested under axial compression. While specimens fabricated separately by HSWEDM and extrusion both exhibited a stable crushing behavior, the extruded ones were much more applicable as lightweight energy absorbers because of their good energy absorption capacity, repeatability, and low cost. The numerically simulated force–displacement curve and the corresponding deformation morphologies of the CSCS compared well with those obtained from experiments. The specific folding deformation mode was revealed from both experiments and simulations. Subsequently, based upon the mode of folding deformation, a theoretical model was established to predict the mean crushing force of the CSCS construction. It was demonstrated that CSCSs with more corrugated units, smaller value of tc/tf and W/Ro could dissipate more impact energy. Such sandwich cylindrical shells exhibited better energy absorption than monolithic cylindrical shells, with an increase of at least 30%. Ultimately, the dynamic effect under the impact load was further evaluated. The dynamic amplification coefficient of CSCS decreased with the increase of the wall thickness.