Experimentally Observed Strain Distributions Near Circular Discontinuities of AA6061-T6 Extrusions During Axial Crush

An experimental investigation to determine the strain distribution and collapse behaviour for AA6061-T6 square cross-sectional extrusions with and without circular discontinuities under quasi-static axial compressive loading was completed. Three-dimensional digital image correlation (DIC) was utilized for strain assessment. In order to validate the results of the optical strain measurement system, tensile tests were first conducted employing both the DIC technique and a traditional extensometer. Strain observations from both methods were found to be very consistent prior to strain localization in the test specimen. Quasi-static axial crushing tests were then conducted. Extrusions considered for the present research had a nominal side width, wall thickness and length of 38.1 mm, 3.15 mm, and 200 mm, respectively. A centrally-located circular hole with diameter of either 14.29 mm, 10.72 mm or 7.14 mm was incorporated into the extrusion. Square tubes without any discontinuities were also considered in the experimental testing program. Testing results showed that the collapse mode of the extrusion altered from global bending to a cutting and splitting deformation mode with the presence of the circular discontinuity. Strain localization occurred near the vicinity of the holes for all specimens. For discontinuities sized 14.29 mm and 10.72 mm the location of strain localization and the initiation of material fracture was at the edge of the discontinuity while the location for extrusions with a 7.14 mm hole was found to occur at the intersection of the extrusion side walls. Maximum values of the effective strain were found to vary from approximately 60% to 100%. The region of strain localization was consistent with the location where material fracture initiated.