Axial crushing of ultralight all-metallic truncated conical sandwich shells with corrugated cores

Novel ultralight all-metallic truncated conical sandwich shells (TCSS) with corrugated cores are designed and fabricated using the molding process. Quasi-static axial compression tests are performed to investigate the crushing behaviors of the proposed structure, with focus placed upon its peak strength and energy absorption capacity as well as the interaction effect of its face-sheets and corrugated core during the crushing process. Detailed parametric study with three-dimensional finite element simulations is subsequently carried out to further explore the failure mechanisms as well as the influence of key geometrical parameters. Finally, the response surface models of specific energy absorption (SEA) and peak force (PF) are established with key design variables, and the Pareto fronts in terms of maximum SEA and minimum PF are obtained. Relative to monolithic conical shells having equal mass, the SEA of the TCSS is significantly greater while the PF is smaller, attractive for energy absorption applications demanding high levels of crashworthiness.