Int. J. Impaot Engng. Vol.l, No.3, pp.

309-317, 1983
Printed in Great Britain

O734-743X/83 $3.OO+O.00 ~1983 Pergamon Press Ltd.

THE EFFECTIVE CRUSHING DISTANCE IN AXIALLY COMPRESSED THIN-WALLED METAL COLUMNS

Polish Academy of Sciences, Institute for Fundamental Technological Research, Swietokrzyska 21, 00-049 Warsaw, Poland (Received 19 April 1983; in revised form 11 May 1983)
- This paper examines the effective crushing distance of thin-walled s. In contrast to previous work on this subject where a perfectly plastic material was assL~ned, the hardening property of a material is now taken into account. A simplified theoretical model of a co~pressed rigidlinearly strain hardening metal strip is studied and a closed-form solution is derived for the crushing distance of unstiffened as well as transversly stiffened box columns. The theoretical predictions are in excellent agreement with experimental data.

INTRODUCTION
The crushing b e h a v i o u r of t h i n - w a l l e d metal columns has been e x t e n s i v e l y studied by various authors using a r i g i d - p e r f e c t l y plastic material idealization. The c r u s h i n g process proceeds p r o g r e s s i v e l y for a sufficiently short column. Once the first fold is formed, either by natural plastic buckling or a preb uck l i n g process, then a column continues to collapse in the same manner and with the same length (2H) of subsequent lobes [5-7]. The fold line is seen to remain in the plane inclined by 45 to the two planes of symmetry of a column cross-section. The folding process of each lobe is limited by the contact of its lower and upper ends. A view of a pertially crushed square column is shown in Fig. I. The interesting feature of this collapse mode o b s e r v e d in experiments is that the fold line forms a shell having double curvature. The small radius of c u r v a t u r e of the shell r, shown in Fig. I is constant along the fold line and is usually of the order of the shell thickness. The second radius of the principal c u r v a t u r e R is much larger and is comparable to the w i d t h of the panel. At the same time, the four sides of the column undergo a cylindrical bending. It is evident that the presence of these radii do significantly influence the effective crushing distance of the column and hence the resulting crushing force. The m a j o r i t y of c o m p u t a t i o n a l models [cf. 5, 6, 9] of the crushing process of columns are based on the assumption that the material is r i g i d - p e r f e c t l y plastic. Such a m a t e r i a l admits slope d i s c o n t i n u i t i e s at stationary hinge lines. Taking the hinge lines to be fixed in the material, as for example in [10] and [11], the radius of the fold line reduces to zero and the effective c rus h i n g distance is equal to the w a v e l e n g t h of the folding mode 2H. In an attempt to obtain a more accurate expression for the internal energy d i s s i p a t i o n of a c o m p r e s s e d tube, A k e r s t r o m and Wierzbicki [12] and more recently A i - H a s s a n i et aZ. [13] c o n s i d e r e d p r o p a ga t i n g hinge lines. One such line bends a flat side plate to a c y l i n d r i c a l surface having a radius r, while the second l i n e flattens out the cylinder back to a plane sheet. The effective crushing distance in this model is equal to 2H-2r. 309

310

Wlodzimierz

Abramowic z

FIGURE I.

View of partially collapsed square c o l ~ n

[7].

COMPUTATIONAL MODEL
The actual folding process of t h i n - w a l l e d columns is much more c o m p l i c a t e d than the simplified picture c o n s i d e r e d in the above m e n t i o n e d references, as can be seen from Fig. I. Looking at a fold line, we observe that the terminal stage of the deformed corner of the column is a result of two subsequent bendings of initially flat metal sheet (Fig. 2). In the "first bending", the initially flat sheet is bent to an angle slightly larger than w and forms the shape shown in Fig. 2(b). The m a x i m u m lift of this bent mode is defined as 2r. Then, the deformed sheet is bent again in the direction p e r p e n d i c u l a r to the "first bending". This process, called the "second bending", is shown in Fig. 2(c). The m a x i m u m lift of the "second bending" mode is defined as 2r + 2R. In the actual folding of a column the sequence of events is different. Both radii are present from the beginning as a section of the toroidal surface travels through the material. It is rather difficult to analyse the problem of a second bending near a fold line. However, near the centre of the column sides, the "second bending" becomes simply a single bending of an initially flat metal strip. In the present c o m p u t a t i o n a l model, it is thus

Crushing

distance

in metal

columns

311

L if
(a)
FIGURE 2.

/
The 'first bending' (b)
Subsecflent bendings of initially flat metal sheet.

The 'second bending" (c)

assumed that radius of the c y l i n d r i c a l bending is governed by folding of side plates rather than by corner lines. The so-called m a x i m u m lift is then controlled by the s t r a i n - h a r d e n i n g p r o p e r t i e s of a material.

AUXILIARY PROBLEM

Let us first consider an auxiliary p r o b l e m of a beam or plate strip with vertical end loads (Fig. 3). The length of the beam is 2L, its thickness H and breadth b. It is assumed that the load remains vertical.

h
A-- ~ -'- " -

j
(b)

rigid

~p~stic

Tp
(a)
FIGURE 3.

(c)

Collapse stages of metal bar.

After the load reaches a critical value the beam buckles and starts to fold. The m a t e r i a l of the beam undergoes a gross plastic d e f o r m a t i o n which spreads over a finite part of the b e a m leading to a certain terminal shape as indicated in Fig. 3. The folding process is symmetric with respect to the horizontal plane A-A Fig. 3, so that only the one-half of the beam shown in Fig. 4 needs to be considered. The b e a m is made of a r i g i d - l i n e a r l y hardening material for w h i c h ~ and E o p are the yield stress and hardening modulus, respectively. N e g l e c t i n g any extensibility of the c e n t r o i d of the beam and the influence of shear forces, the moment c u r v a t u r e r e l a t i o n s h i p is taken to be [I, 3]

312

Wlodzimierz

Abramowicz

P [-i(3

im

P r
/rll

lll;;l

FIGURE 4. M

Initial and current configuration of compressed bar. _> M 0

< =

M 0

~p i
M < M0 fully plastic moment of the c r o s s - s e c t i o n and I denotes the

(I)

t 0 where second M 0 is the moment

of area

of the c r o s s - s e c t i o n .

E q u a t i o n (I) implies that the a n a l y s i s will be c a r r i e d out using the d e f o r m a t i o n t h e o r y of p l a s t i c i t y . This is p e r m i s s i b l e as long as no strain r e v e r s a l takes place. Indeed, w i t h an a s s u m p t i o n that the i n f l u e n c e of axial stress and strain is n e g l e c t e d , the b e n d i n g s t r e s s e s do not c h a n g e sign and no local unl o a d i n g takes place. A s i m i l a r p r o c e d u r e was d e v e l o p e d in [2] and has p r o v e d very h e l p f u l in a c c u r a t e l y p r e d i c t i n g the c r u s h r e s i s t a n c e of m e t a l rings. As a c o n s e q u e n c e of e q u a t i o n (I), the d e f o r m a t i o n w i t h i n p l a s t i c flow can be a n a l y s e d by e q u a t i o n s w h i c h are f o r m a l l y used in the s t a n d a r d e l a s t i c a t h e o r y [4]. This not have s o l u t i o n c o n s t i t u t e s a set of n o n l i n e a r an e x p l i c i t solution. equations the zone u n d e r g o i n g a n a l o g o u s to those

which

generally

do

However, from the p o i n t of v i e w of the p r e s e n t l y c o n s i d e r e d p r o b l e m of c r u s h i n g m e c h a n i c s it is n e c e s s a r y to c a l c u l a t e o n l y the m a x i m a l h e i g h t of the d e f o r m e d b e a m shown in Fig. 3(c). This can be done as i l l u s t r a t e d in the f o l l o w i n g section. Let us take the angle of inclination u L of the r i g i d zone in Fig. 4 as an

i n d e p e n d e n t v a r i a b l e of the p r o c e s s and c o n s i d e r m o m e n t e q u i l i b r i u m at the p o i n t B w h i c h s e p a r a t e s the zone u n d e r g o i n g p l a s t i c flow from the rigid one. For the p r e s c r i b e d angle u L, we have from Fig. 4 Pa sin For u L = M 0. u L the a l r e a d y mentioned elastic solution [4] y i e l d s (3) (2)

the p r e s c r i b e d P = ~
8 2

EpI

Crushinq

distance

in m e t a l

columns

313

where

and K ( s i n ) and E ( s i n the i n c o m p l e t e e l l i p t i c Substituting

) are the c o m p l e t e and F(sin -;- ) and K ( s i n -;- ) are i n t e g r a l s of the first and s e c o n d kinds, r e s p e c t i v e l y . (2) one o b t a i n s

into e q u a t i o n
M0

Ep

a sin u L

(4)

Now,

f r o m Fig.

= L - a so that after
a
= -

introducing L

a dimensionless

parameter (5)

we have

the e2

following - ~(2

quadratic

equation + I = 0

for (6)

+ B 2 ~2 sin u L) parameter:

where

the d i m e n s i o n l e s s

d e s c r i b e s the g e o m e t r i c a l and m a t e r i a l p r o p e r t y (2) that the s o l u t i o n (6) lies w i t h i n the range It s h o u l d be n o t e d that this s o l u t i o n shape of a b e a m c r o s s - s e c t i o n . does

of the beam. 0 5 ~ ~ I. not impose any

It follows

from

limitations

upon

the

Following the s t a n d a r d s o l u t i o n [4] we u t i l i z e the e q u a t i o n c o o r d i n a t e of the d e f o r m e d c e n t r o i d of the b e a m Fig. 4 x_~ = 2 E ( s i n Using B relation uL for the XL c o o r d i n a t e ~_LL) I.

for the x

(7)

the g e o m e t r i c a l

XL = x + a cos we a r r i v e at an e q u a t i o n XL L This expression given

(8) at one end of the b e a m

(I - ~)

[2E in -~[-the XL/L

+ ~ cos u L. as a f u n c t i o n of u L. Having found

(9) the

describes by

ratio

solution

(8) one can e a s i l y XL/L ratio.

obtain

the c o n d i t i o n

for the m a x i m a l

lift

of the b e a m

for e a c h

The c u r r e n t
--=-

coordinate UL -~;

of the b e a m c e n t r e l i n e ~) - F ( s i n - ~ -UL ; ~)]

was g i v e n

in

[4] as
(10)

7 ~E(sin B UL,

For

the p r e s c r i b e d

the c o n d i t i o n

for the m a x i m u m

lift of the b e a m

is

[4]

314

Wlodzimierz

Abramowic z

~ = arc sin (

/2 1 2 sin(UL/2) integrals.

(11)
Substi-

where ~ is the independent variable of incomplete elliptic tuting = L(I - 6) into (10) we have

Xmax - I-~ [2E(sin(UL/2);~) - F (sin(UL/2);~)] B

(12)

It is interesting to note that the solution of (9) and (12) exhibits a weak dependence on the dimensionless parameter I varying in the range from 2.5 to infinity as shown in Fig. 5.

L 1.0

0.2
0
FIGURE 5.
' 1.0 ' 2.0

"-y

3'.o

- X

1/L ratio versus dimensionless parameter I. it was observed that for I > 2.5 and u L > ~/2 the differ-

On the other hand, ence between regarded X L from

(9) and x L from

(7) is of the order of 3% and may be disto give the simple expressions

in the first approximation,

--

---

(13)

and XLaX ~ 1 [2E(sin 2 ; ~ I provided

F[sin 2;~) ]

(14)

I = --P-- > 2.5. M0L -

(14a)

These expressions are formally analogous to those derived in the theory of elasticity where the same simplifications were used. It is important to note that the maximum lift of the beam is independent of the material and geometrical properties of the beam cross-section provided I ~ 2.5. APPLICATION TO FOLDING OF COLUMNS

Now we are in the position to use the above developed theory to determine the effective crushing distance of two kinds of box columns frequently used in engineering practice. One such column was shown in Fig. I. The second column differs from the first one in that it possesses horizontal stiffeners which influence significantly the deformation mode of crushed columns. The differences

C r u s h i n g d i s t a n c e in metal columns

315

are s c h e m a t i c a l l y given in Fig. 6. The unStiffened column buckles with subsequent lobes formed symmetrically on both sides of the llne representing the

/~iguration

L..-undeformed

l
/

undeformed

configuration

entire /( lobe of tength 2H

entire robe [f~-~ J of [enc~h2H I ~ - J (b) I

Terminal configuration of collapsed box column.

u n d e f o r m e d shape of adjacent lobes. In prevent rotation of shape of the lobe. 2H.

the column (Fig. 6a) and there is a smooth transition between the case of stiffened columns, the horizontal stiffeners the ends of each lobe leading to the different terminal In both cases the length of the entire lobe is defined as

Figures I and 6 show that whilst initial bending is analogous for both d e f o r m a t i o n modes and the equivalent length L of the bent sheet is equal to L = /~H then in the second bending Fig. 2(c) equivalent lengths are L = ~H for the box column without stiffeners and
L = ~- ~/2H

(15)

(16)

(171

for the stiffened column, respectively. Let us examine now the terminal stage of initial bending. This stage is defined by the c o n d i t i o n x L = 0(Fig. 2b) which using (13) gives

- 1 = 0.

1181 114) we have

Solving this equation with respect to u L and substituting back into

max L

0.26.

(19)

On the other hand, the terminal stage of the second bending occurs when Xma x = 2x L (compare Fig. Ic and Fig. 7). (20)

lit is easy to show that 114) is always fulfilled since I > 10 for columns frequently used in engineering practice.

316

Wlodzimierz Abramowicz

Using

(14) and

(13) gives the following condition UL F ~in T;

2E(sinT ; ~) UL
x max ~ 0.28 L

~) = 2[E(sin ~)

I]

(21) Solving

for the angle uL chosen as an independent variable of the process. this expression with respect to u L and substituting back into

(14) one obtains (22)

so that the final lift of a double bent sheet shown in Fig.

7 is

6I : x(2)max + ~

~ 0.59H

(23)

for the box column without horizontal stiffeners and

(1)
~ 0.78H
stiffeners. (24)

6II

= 2x(21
max

+ 2 --~

for the box column with horizontal

In both cases the initial height of the u n d e f o r m e d column was 2H. Let 6 denote a vertical d i s p l a c e m e n t of the upper end of the column from the undeformed c o n f i g u r a t i o n to the stage shown in Fig. 7. The effective shortening of the

Box column without stiffeners

Stiffened box column

Illll

~Xf;"

L- V~'H \
(o)
FIGURE 7.
.E x

(b)

Effective crushing distance - computational model.

column is then

6I ~
2H

= 0.70

(25)

for the box column without stiffeners and

2H~ 0.60
for the stiffened box column.

(26)

Thus, the effective crushing distance of box members is about 70% of its original height in the case of an u n s t i f f e n e d column and about 60% in the case of column with horizontal stiffeners.

1'2Superscripts (I) and (2) denotes the first and second bending, respectively.

C r u s h i n g distance in metal columns

317

CONCLUSIONS A simplified m e t h o d for the d e t e r m i n a t i o n of the effective crushing distance of c o m p r e s s e d box columns is p r e s e n t e d in this paper. In contrast to previous works on this subject the effect of the strain hardening of the material is taken into account. The crushing distance is predicted with very good accuracy despite a rather simple c o m p u t a t i o n a l model. Experimental results reported for example in [5] and [6] show that the crushing distance of unstiffened box columns is equal to about 70% of the original height of the member. This result is in excellent agreement with the p r e d i c t i o n of (25). On the other hand, it was shown on empirical grounds in [8] that the crushing distance of stiffened box columns is 2/3 of its original height. This result also correlates well with theoretical p r e d i c t i o n s of (26). It should be noted that the theoretical relations describe only the process of p r o g r e s s i v e crushing of box columns. It was tacitly assumed that the crushing process proceeds until the last lobe is created and this configuration is defined as a terminal stage of column deformation. The crushing process may proceed further but in this stage the crushing loads would be much larger than those e n c o u n t e r e d in progressive folding. This phase of deformation was not considered here.

REFERENCES E. T. Onat, On certain second order effects in the limit design of frames, J. Aerospace Sci., 222, 681-684 (1955). 2. S. R. Reid and T. Y. Reddy, Effect of strain hardening on the lateral ceapression of tubes between rigid plates, Int. J. Solid Struc., 14, 213-225 (1978). 3. S. R. Reid and T. Y. Reddy, Effects of strain hardening on large plastic deformation of cantilever, J. Appl. Mech., 45, 953-955 (1978). 4. E. P. IM~0ow, Nonlinear statiC-analysis of flexible bars. Science and Technology Publicati~ Moscow (1948). (In Russian.) 5. Y. Ohokubo, T. Akamatsu and K. Shirasawa, Mean crushing strength of closed-hat section members SAE paper 740040. Detroit (1974). 6. W. Abramowicz, Simplified crushing analysis of thin-walled columns and beams, Eng. Trans. 29, 5-26 (1981). 7. T. Wierzbicki, On the formation and growth of forming modes, M.I.T. report no. 82-5 (1982). 8. T. Wierzbicki, W. Abramowicz and J. de Oliveira, Crushing analysis of ship structures with particular reference to bow collisions. Det norske VERITAS technical report no. 82-0709 (1982). 9. T. Wierzbicki and W. Abramowicz, On the crushing mechanics of thin-walled structures, J. Appl. Mech., 50 (1983). 10. A. G. Pugsley and--M. A. Maculay, The large scale crumpling of thin cylindrical columns, Quart. J. Mech. Appl. Math., I_/3,I-9 (1960). 11. W. Johnson, P. D. Soden and S. T. S. Ai-Hassani, Inextensional collapse of thin-%~lled tubes under axial compression, J. Strain Analysis, 12, 317-330 (1977). 12. T. Wierzbicki and T. Akerstrom, Dynamic crushing of strain rate sensitive box columns, SAE paper no. 770592. Proc. 2nd Int'l. Conf. Vehicle Struc. Fech,, Southfield, MI, 19-31, 18-20 April (1977). 13. Q. Meng, S. T. S. Ai-Hassani and P. D. Soden, Axial crushing of square tubes, Presented at the First International Symposium on Structural Crashworthiness, University of Liverpool, 14-16 S e p t ~ r (1983). Published in Int. J. Mech. Sci., 25, no. 9 (1983). I.