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This paper presents an experiment and an analysis for examining the variation of the 90° redundanthole diameter effect on the cyclic bending mechanical behavior and fracture failure of round-hole 6061-T6 aluminum alloy tubes. In this investigation, a round-hole 6061-T6 aluminum alloy tube with a 6 mm hole diameter was drilled to obtain a 90° redundant hole but with different hole diameter of 2, 4, 6, 8, or 10 mm. It can be observed that from the first bending cycle, the bending moment-curvature curve describes a stable loop. The diameter of the 90° redundant hole has little effect on the bending moment-curvature relationship. However, when the number of bending cycles increases, the ovalization-curvature curve shows an increasing, asymmetrical, ratcheting, and bow-like tendency. The diameter of 90° redundant-hole shows a significant influence on the ovalization-curvature relationship. In addition, five non-parallel straight lines corresponding to five different 90° redundant hole diameters were discovered for the controlled curvature-number of bending cycles necessary to cause failure relationship on the double logarithmic coordinates. Finally, a formula was presented to simulate the above relationship. It is found that the experimental and analytical data were in good agreement.

Variation of the 90° Redundant-hole Diameter Effect on the Response and Failure of Round-hole 6061-T6 Aluminum Alloy Tubes under the Cyclic Bending