@article{LI2026, 
author = {Qiqi LI and Shengze RAO and Tiefang ZOU},
title = {Design of a finite element simulation platform for investigating the crushing mechanisms of multi-material structures},
year = {2026},
journal = {Experimental Technology and Management},
volume = {43},
number = {7},
pages = {166-175},
keywords = {CFRP tubes, Al/CFRP hybrid tubes, axial crushing, finite element simulation, progressive damage},
url = {https://www.sciopen.com/article/10.16791/j.cnki.sjg.2026.07.019},
doi = {10.16791/j.cnki.sjg.2026.07.019},
abstract = {ObjectiveCarbon fiber reinforced polymer (CFRP) thin-walled structures are widely used as core materials for lightweight energy-absorbing components in the aerospace and automotive industries owing to their exceptionally high specific stiffness, specific strength, and specific energy absorption (SEA). However, CFRP tubes face limitations in engineering applications, including high manufacturing costs and a tendency toward sudden brittle failure during crushing. To address these shortcomings, combining highly ductile metals with CFRP to form multi-material hybrid tubes has become an active area of research. Because traditional methods and costly physical experiments cannot readily quantify internal damage mechanisms, this study aimed to develop a high-precision finite element simulation platform. The platform overcomes technical barriers such as three-dimensional progressive damage modeling, thereby strengthening students’ ability to analyze crushing failure mechanisms and multi-material composite effects.MethodsThis study adopted a combined experimental and numerical approach. First, quasi-static axial crushing experiments were performed on CFRP square tubes prepared through a vacuum bag hot-pressing process. The tubes, consisting of five alternating layers of 0° and 90° carbon fiber prepreg, provided real force–displacement responses and macroscopic deformation modes for baseline verification. Second, the finite element simulation platform was built using the ABAQUS/Explicit solver. To accurately characterize intralaminar damage in composite materials, a VUMAT user-defined material subroutine was developed through Fortran programming to implement the updated three-dimensional Hashin progressive failure criterion. This mathematical model evaluates fiber tension/compression and matrix tension/compression damage in real time, executing stiffness degradation and element deletion once the ultimate failure thresholds are reached. In addition, cohesive elements governed by a traction–separation law and a quadratic nominal stress damage criterion were inserted between composite plies to simulate interlaminar delamination. Finally, using the verified platform, an extended study on aluminum/carbon fiber (Al/CFRP) hybrid tubes was conducted. Two distinct configurations were designed based on the stacking sequence: the C-A tube (an aluminum outer tube with a CFRP inner layer) and the A-C tube (a CFRP outer tube with an aluminum inner layer). The dynamic evolution processes and interfacial coupling mechanisms of these structures under identical axial crushing conditions were systematically analyzed and compared.ResultsThe experimental and simulation results indicated the following: 1) The platform accurately replicated the macroscopic progressive instability and microscopic brittle fracture of CFRP tubes, with the errors in core energy absorption indicators held within 5%; 2) As the lamination sequence changed, the failure modes exhibited entirely opposite composite effects; 3) The A-C configuration experienced early outward tearing, leading to premature loss of lateral constraint and rapid disappearance of the composite effect; 4) Conversely, the C-A configuration effectively suppressed the peeling and chaotic delamination of the internal CFRP layer through the strong hoop constraint provided by the external aluminum tube. Compared with the CFRP tube, the energy absorption (EA), mean crushing force (MCF), and SEA of the C-A configuration increased by 269.42%, 269.61%, and 37.47%, respectively.ConclusionsThe platform proves to be a highly reliable tool for analyzing the complex failure mechanisms of anisotropic materials. The study demonstrates that introducing metal into composite structures fundamentally mitigates sudden brittle failure, achieving deep interfacial synergy. Furthermore, the teaching cases developed through this platform enable students to systematically master crushing experimental methods, finite element modeling, and comparative analysis strategies within a limited timeframe. This approach overcomes the observational limitations of physical experiments and considerably deepens students’ understanding of synergistic failure mechanisms in complex engineering structures.}
}