Theoretical prediction model for the compressive behavior of the hybrid tube considering compression angle

Abstract The oblique collision happening in vehicle accidents poses a huge threat to passive safety, which causes great difficulties in the design of energy absorption (EA) structures and the prediction of EA capacity due to its highly nonlinear deformation characteristics. This study aims to establish a theoretical prediction model for the compression performance of Carbon Fiber Reinforced Polymer (CFRP)/Al hybrid tube considering the loading angle. First, a high‐precision FE model was established to obtain the influence laws of tube diameter, Al thickness, and CFRP thickness on the crashworthiness of CFRP/Al hybrid tubes, laying the foundation for subsequent theoretical model validation. Second, by summarizing the deformation modes of hybrid tubes generated by various parameter combinations, a modified global origami deformation assumption was proposed under multi‐angle compression conditions, and the key terms in energy composition are extracted based on the initial and final states of folding elements. Third, a theoretical model for predicting the mean crushing forces (MCFs) of hybrid tubes was established by revealing the correlation mechanism between energy composition terms and loading angle. Finally, the theoretical prediction model was validated by experiment and simulation results and the application premise was given. Results showed that the theoretical prediction model was proved to be of high accuracy, as the average absolute prediction errors of MCF under axial, 10°, 20°, and 30° compression conditions were 6.54%, 4.63%, 3.72%, and 3.93%, respectively. This study provides valuable guidance for the forward design and development of multi‐material hybrid structures facing complex crushing conditions. Highlights An analytical model of the hybrid circular tubes considering compression angle is newly proposed. Deformation mode and axial crushing response are analyzed by experiments. The major energy dissipation mechanism for hybrid circular tubes is explicitly derived. The Al thickness has the most significant impact on energy absorption. The recommendations for the design and development of hybrid tube are provided.