The main focus of this research was to investigate force/displacement response and energy absorption performances of axially loaded AA6061 T4 and T6 circular aluminum alloy extrusions under cutting deformation mode. Quasi-static experimental investigation on load/displacement and energy absorption characteristics under cutting deformation mode was completed utilizing specially designed heat-treated 4140 steel alloy cutters and two different geometries of the cone-shaped deflectors. An almost constant force during cutting was observed, which eliminated high peak crush force associated with progressive folding or global bending deformation modes. Additionally a dual stage cutting process was initiated using two cutters in series in this research. In addition to cutters and deflectors, spacers of different geometries between the cutters were also incorporated in this study. Finally to this research, a numerical study of the axial cutting deformation process was simulated employing an Eulerian and Smoothed Particle Hydrodynamic (SPH) methods.

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