In order to improve the simulation accuracy of composite tube crush by finite element method, a nonlinear progressive damage model predicting the progressive inner-lamina damage of laminates is implemented. Each element of FEM is defined by the model. All parameters in this model were identified according to the published test data. The longitudinal crush was simulated by the solver of ABAQUS /explicit using the nonlinear progressive model. The result shows that the failure form pattern, peak force and energy absorption fit well with the published experimental ones. The robust optimization based on Six sigma technology and probability distribution of design variables is carried out to obtain an improved energy absorption property instead of deterministic optimization. This method can obtain an optimal composite tube with stable high energy absorption capability in a practical manufacture process.

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