Crashworthiness optimization of empty and filled aluminum crash boxes

Abstract

Dynamic crash tests on empty, honeycomb-filled and foam-filled square aluminum tubes have been performed. Furthermore, in order to find more details about crash processes, finite element simulations of the experiments have been done. In terms of finding more efficient and lighter crash absorbers and achieving maximum energy absorption, Multi design optimization (MDO) technique has been applied for optimizing the square and circular tubes. Based on practical requirements the optimum tube geometry which absorbs maximum energy and has a minimum weight has been determined. The results of simulations of filled identical tubes with honeycomb and foam with the same density showed that the foam behaves better than honeycomb. Results of previous work indicated that using high density honeycomb for filling the tubes will result in more energy absorption but the weight efficiency has been lost (H R Zarei, M Kröger M and K Popp, 'Experimental and numerical quasi static crash investigation in empty and honeycomb filled aluminum square tubes ', Int J Crashworthiness, May 2005, submitted). Therefore, a comprehensive study has been performed in order to find out the crash behavior of tubes filled with foam with different densities. The MDO procedure has been implemented to find an optimum filled tube that absorbed the same energy as an optimum empty tube can absorb.

Crashworthiness response of honeycomb metallic-GFRP energy absorption devices

“…However, if they are combined with the ductile and progressive collapse of a metal part, the combination can offer higher values of absorbed energy for a very minor increase of the overall weight. The mean crushing strength of a metal tube filled with a honeycomb structure is therefore increased when compared to the empty one [10]. Therefore, complementing the metal tube with a core material translates into a better crashworthiness of the specimen, since the energy absorption values are higher and the overall weight of the car can be reduced.…”

Dynamic crashing behavior of new extrudable multi-cell tubes with a functionally graded thickness

“…In this study, the crashworthiness performances were assessed for the same crash displacement (δ ¼110 mm herein) for all tubes, which was commonly used by other researchers [39][40][41][42].…”

Dynamical bending analysis and optimization design for functionally graded thickness (FGT) tube

“…Apparently, the higher the SEA, the better the energy absorption capacity of a structure. Another indictor in relation to energy absorption capacity is crash force efficiency (CFE), which can be given as [45].…”