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This research presents a comprehensive investigation into the effect of slenderness ratio and polyurethane foam (PUF) density on the axial compressive behaviour of foam-filled steel and aluminium tubes. Experimental studies were conducted on tubes with varying slenderness ratios and filled with low, medium and high-density PUFs to assess improvements in energy absorption, compressive strength, and buckling resistance. The role of slenderness ratio in inducing local and global buckling modes was systematically examined. Finite element simulations were carried out using both ANSYS and ABAQUS software to replicate deformation patterns, failure modes, and post-buckling responses observed in the experiments. The results from both numerical platforms showed close agreement with experimental peak load values, with deviations generally within ±8–10% for most configurations. While this accuracy was consistent for peak load prediction, variations in other response parameters across the 18 tested configurations suggest that caution is needed before generalising beyond the studied cases. Both platforms nevertheless reproduced key experimental trends, highlighting the synergistic influence of higher PUF density and increased slenderness ratio in delaying local buckling and improving structural performance. This dual-software validation strengthens the reliability of the numerical models and confirms the potential of foam-filled slender tubes in applications demanding lightweight and high-stability structures. The study establishes an integrated experimental–computational framework for optimizing slender structural elements in aerospace, automotive, and civil infrastructure systems.

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Influence of Polyurethane Foam Density and Slenderness Ratio on the Axial Compression Behaviour of Foam-Filled Tubes: Experimental and Numerical Analysis Using ANSYS and ABAQUS

  • 会议论文

  • 发表日期：

    2026年

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  • Sunkesula Sudhakar,
  • B. Jayarami Reddy

摘要

This research presents a comprehensive investigation into the effect of slenderness ratio and polyurethane foam (PUF) density on the axial compressive behaviour of foam-filled steel and aluminium tubes. Experimental studies were conducted on tubes with varying slenderness ratios and filled with low, medium and high-density PUFs to assess improvements in energy absorption, compressive strength, and buckling resistance. The role of slenderness ratio in inducing local and global buckling modes was systematically examined. Finite element simulations were carried out using both ANSYS and ABAQUS software to replicate deformation patterns, failure modes, and post-buckling responses observed in the experiments. The results from both numerical platforms showed close agreement with experimental peak load values, with deviations generally within ±8–10% for most configurations. While this accuracy was consistent for peak load prediction, variations in other response parameters across the 18 tested configurations suggest that caution is needed before generalising beyond the studied cases. Both platforms nevertheless reproduced key experimental trends, highlighting the synergistic influence of higher PUF density and increased slenderness ratio in delaying local buckling and improving structural performance. This dual-software validation strengthens the reliability of the numerical models and confirms the potential of foam-filled slender tubes in applications demanding lightweight and high-stability structures. The study establishes an integrated experimental–computational framework for optimizing slender structural elements in aerospace, automotive, and civil infrastructure systems.