Abstract:
To investigate the crushing response and damage evolution of tubes with various hybrid structural configurations, as well as the correlation mechanism between structural configuration and mechanical properties, this study fabricated a braided-wound-laid hybrid carbon fiber reinforced polymer circular tube using an automated braiding-winding-pultrusion production line and established a corresponding numerical model. The validity of the model for crashworthiness research on hybrid circular tubes was verified through axial crushing tests. The results demonstrate that the simulated force-displacement curves and crushing morphologies are in excellent agreement with the experimental data, with the errors of various crashworthiness indicators ranging from 2.11% to 8.60%. Further analysis was conducted on the effects of the braided layer's position on the failure modes and crashworthiness indicators of the hybrid tubes. It was revealed that the outermost braided layer has a substantial impact on load-bearing capacity. Its removal leads to a 29.99% reduction in peak crushing force and a 36.82% decrease in mean crushing force. Replacing it with a laid-up layer reduces these forces by 25.11% and 19.72%, respectively, whereas replacing it with a wound layer yields reduction of 12.54% and 14.72%, respectively. Conversely, removing or replacing the outermost braided layer increases the total energy absorption by 2.02%–24.70%, but decreases the specific energy absorption by 12.85%–21.02%. In conclusion, the structural configuration significantly affects the failure modes and load-bearing/energy-absorbing responses of the braided-wound-laid hybrid circular tubes under quasi-static compression, with inconsistent impacts on various crashworthiness indicators.