Reliable design of corrugated fibre‑reinforced polymer (FRP) tubes requires explicit consideration of mesoscale damage mechanisms and their probabilistic interaction under multiaxial loading. This study develops a three‑dimensional finite‑element framework that integrates a bilinear cohesive‑zone model with Puck’s action‑plane failure criterion to capture delamination, intralaminar cracking, and stiffness degradation across multilayer laminate architectures. A structured design‑of‑experiments strategy is employed to evaluate the influence of adhesive properties, loading paths, and laminate configuration, including fibre orientation, ply count, ply thickness, and transverse modulus. Nonlinear surrogate limit‑state functions extracted from the simulations enable generalised Puck‑based safety factors for combined loading conditions. Monte Carlo reliability analysis reveals a four‑order‑of‑magnitude reduction in failure probability under tensile loading as the safety margin increases from 0.9 to 1.4, whereas compressive loading remains reliability‑limited due to the inherent compression sensitivity of multilayer laminates. The results demonstrate that deterministic stiffness and strength enhancements alone do not guarantee structural integrity. The proposed formulations provide quantitative guidance for the probabilistic design of corrugated FRP tubes under multiaxial loads, supporting resilient infrastructures in pipeline and aerospace applications. • Puck-CZM framework details intralaminar-interlaminar failure cascade. • Non-monotonic reliability sensitivity to E 2 n and G Ic is identified. • Compressive failure is limited by displacement more than material strength. • Compressive mode shows persistent reliability concerns under multiaxial loading. • Tensile P f drops 4 orders of magnitude but compressive P f saturates high.
Savari et al. (Sun,) studied this question.