• Plastic Collapse;
  • Grooved Conical Tube;
  • Polyurethane Foam

In this article, an experimental study is presented to investigate the crushing behavior and energy absorption of empty and polyurethane foam-filled thin-walled aluminum grooved conical tubes under axial compression. In this innovative design model, the plastic hinges occur at predetermined intervals along the tube, by creating the circumferential grooves from the outer and inner surface of conical. The energy absorption ability of empty and foam-filled grooved conical tubes due to plastic deformation in a crushing process is evaluated. The results show that the load–displacement curve and energy absorbed by the axial crushing of tubes can be controlled by filling them with appropriate lightweight materials and grooves number. Therefore, the results from this study will assist automotive industry to design crashworthy components based on the grooved conical tubes.