Axial crushing of square crash boxes (CBs) is a complex phenomenon in which the unrepeatability of the tests is quite common. Conducting an acceptable experiment that can be used for validating a finite element (FE) setup is normally based on the researcher's experience. The researchers deal with a large number of irreproducible test results. Likewise, the FE simulations face the same issue, owing to the high sensitivity of the stability simulations, which can crucially mislead the FE outcomes. These uncertainties decrease the reliability of the results of the studies. The present study focus on this issue. It examines the compression behavior of the CBs and the effect of the imperfections and explains the resources of this irreproducibility. Furthermore, it analyzes the production of the different folding patterns and shows that buckling coupling of the square CB and its side plates results in different folding patterns.
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