Showing papers on "Crash box published in 2020"

A review on crashworthiness studies of crash box structure

Abstract: Many studies have focused on the topic of vehicle safety, including the study on crashworthiness. In vehicle, a crash box structure is an integral component for ensuring the safety of a car. It serves as an energy-absorbing member, together with the front bumper in case of frontal collision during car accidents. Therefore, special attention has to be given towards this structure in order to have better understanding regarding its mechanism of deformation and absorbing kinetic energy from the collision, as well as on how to obtain good crashworthy properties from this structure. This study, primarily, is based on extensive literature survey pertaining to the topic of crash box. As the topic of energy-absorbing member in a car is extensive, this review solely focuses on crash box structure. The main motivation of this paper is to summarise the different approaches and aspects of researches performed on car crash box structure to gain comprehensive knowledge regarding the study on crash box.

Conceptual design of oil palm fibre reinforced polymer hybrid composite automotive crash box using integrated approach

Abstract: A hybrid conceptual design approach was introduced in this study to develop a conceptual design of oil palm polymer composite automotive crash box (ACB). A combination of theory of inventive problem solving (TRIZ), morphological charts and biomimetics was applied where the foremost requirements in terms of the material characteristics, function specifications, force identification, root cause analysis, geometry profile and design selection criteria were considered. The strategy was to use creations of nature to inspire five innovative conceptual designs of the ACB structure and the AHP method was applied to perform the pairwise analysis of selecting the best ACB conceptual design. A new conceptual design for a composite ACB was conceived bearing in mind the properties of natural fibre, unlike those of conventional materials such as steel alloys and aluminium alloys. The design with the highest ranking (26.6 %) was chosen as the final conceptual design, which was the one with a honeycomb structure for the outermost profile, reinforced with a spider web structure inside the part, supported by fibre foam structure extracted from the woodpecker sponge tissue at the centre to maximize the energy absorption capability. The new design could solve the problem of bending collapse which is a major cause of failure to absorb maximum impact energy for ACB during collision. However, the final conceptual design will still need several modifications for production and assembly purposes, which will be completed in a further study.

Modeling and multi-objective optimization of a bionic crash box with folding deformation

Abstract: Traditional crash box is unable to efficiently solve the problem of bending deformation during the collision process, which limits the energy absorption performance and crashworthiness. This paper introduces the structure of cactus into the design of crash box and attempts to redesign a new one with stable folding deformation. By imitating the cactus characteristic, the bionic crash box consists of two parts: one is the corrugated angular structure, and the other is its thickness functionally gradient distribution along the axial direction. Based on the sensitivity analysis, the parameters which have great influences on the energy absorption performance are selected as the design variables. The multi-objective optimization design is conducted based on response surface model and Latin hypercube design of experiment. Simulation results show that the bionic crash box can effectively weaken the damage to the autobody and improve the energy absorption performance through stable folding deformation.

Materials selection of “green” natural fibers in polymer composite automotive crash box using DMAIC approach in Six Sigma method:

Abstract: This article presents the results of research in selecting the most appropriate natural fibers to be used as reinforcement (normally in the hybrid form) in polymer composites for the automotive cra...

Predicting Composite Component Behavior Using Element Level Crashworthiness Tests, Finite Element Analysis and Automated Parametric Identification.

Abstract: Fibre reinforced plastics have tailorable and superior mechanical characteristics compared to metals and can be used to construct relevant components such as primary crash structures for automobiles. However, the absence of standardized methodologies to predict component level damage has led to their underutilization as compared to their metallic counterparts, which are used extensively to manufacture primary crash structures. This paper presents a methodology that uses crashworthiness results from in-plane impact tests, conducted on carbon-fibre reinforced epoxy flat plates, to tune the related material card in Radioss using two different parametric identification techniques: global and adaptive response search methods. The resulting virtual material model was then successfully validated by comparing the crushing behavior with results obtained from experiments that were conducted by impacting a Formula SAE (Society of Automotive Engineers) crash box. Use of automated identification techniques significantly reduces the development time of composite crash structures, whilst the predictive capability reduces the need for component level tests, thereby making the development process more efficient, automated and economical, thereby reducing the cost of development using composite materials. This in turn promotes the development of vehicles that meet safety standards with lower mass and noxious gas emissions.

The influence of crash initiator placement towards the application of energy crash box due to impact load

Abstract: Crash box is one of the passive safety systems located between the bumper and main frame of the vehicle. The main function of the Crash box is to absorb energy due to collisions or collisions experienced by vehicles. Crash box has various forms of diverse cross sections. Although it has a cross-section of diverse, however opportunities to improve the energy absorption in a crash box is still quite high. One of them is given a crash initiator. Crash initiator Air the potential to increase the value of energy absorption. The purpose of this study is to analyze the effect of crash initiator on the absorption of crash box energy due to impact loads. This study targets the development of the value of energy absorption effectively by providing crash initiator equalization. The achievement of initial research is to provide equalization of the crash initiator using the finite element method through ANSYS software with the Geometry of the crash box used circle, hexagonal, and origami trapezoid. Each type of crash box is given equal distribution of crash initiator to increase the absorption of energy obtained after getting an impact load. Furthermore, an experimental study to compare the values obtained between simulation and experiment.

Characteristics of Deformation Pattern and Energy Absorption in Honeycomb Filler Crash Box Due to Frontal Load and Oblique Load Test

Abstract: A crash box design is developed to enhance the crash box’s abilities to absorb crash energy. Previous research has developed the crash box by adding filler material. Adding the filling material to the crash box will increase energy absorption. Aluminum honeycomb has a combination of lightweight mass and an ability to absorb crash energy. The addition of filler material to the crash box will also reduce the possibility of global bending in the crash box. The method of study is a computer simulation using ANSYS Academic software ver 18.1. This research used circular, square and hexagonal cross-section variations, which reached the same cross-sectional area design. Geometry model for the crash box and honeycomb filler is defined as crash box thickness (tc) 1.6 mm, honeycomb filler thickness (t) 0.5 mm for single layer and 1 mm for double layer and crash box length (l) 120 mm. The materials used were AA6063-T6 for crash boxes and AA3003 for honeycomb fillers. The test model consisted of two types, namely frontal load and oblique load test. The impactor velocity (v) is set to 15 m/s. The impactor and the fixed support are modeled as a rigid body, while the crash box is assumed as an elastic body. Observations were done by using the characteristics of deformation pattern and the absorption amount of produced energy due to the given loading model. Based on the deformation pattern results, it can be found that in the crash box model with square and hexagon honeycomb filler, the occurred deformation pattern was concertina, while the crash box with circular honeycomb filler was the mixed mode in the frontal load test. Regarding the oblique loads, the crash box remains to collapse the global bending on all models. Simulation results with the frontal load test model found that the crash box with circle-shaped honeycomb has the highest energy absorption while the crash box with hexagonal honeycomb filler has the highest Specific Energy Absorption (SEA). In the oblique load test, it was found that the crash box with hexagonal honeycomb filler has the highest energy absorption and SEA. By comparing the hexagonal crash box model with and without honeycomb filler, it is noted that the hexagonal crash box with honeycomb filler has higher Crash Force Efficiency

Analysis of multi-cell hexagonal crash box design with foam filled under frontal load model

Abstract: This study aim is to determine the effect of Multi-Hexagonal crash box design variations on energy absorption. The research method used ANSYS Academic software version 18.1. The crash box model analysed consists of 3 models, namely the multi-cell hexagonal outer foam filled crash box, inner foam filled and without foam filled. Crash box testing refers to the instrumented drop mass setup test model, impactor with a mass of 103 kg crashing crash box with a speed of 7.67 m/s. Deformation pattern and energy absorption are observed as design criteria to determine the best crash box design specifications. The simulation results show that the highest energy absorption value is the multi-cell hexagonal outer foam filled crash box with that Ea is 30, 606 kJ. There is a significant difference between the multi-cell hexagonal crash box model with foam filled and without foam filled. The addition of foam filled on the multi-cell hexagonal crash box has important effect to improve energy absorption performance. The deformation pattern that occurs in all three models is concertina mode. Based on the force reaction-displacement curve, it can be denoted the crash box that uses foam filled produces upward trend of curves in the end of the deformation. It can be connected to deformation pattern, folding increment is more identified compared to crash box without foam filled.

Techniques for correlation of drop weight impact testing and numerical simulation for composite GFRP crash boxes using Ls-Dyna

Abstract: Composite materials are being widely used in automobile industry in order to meet the ever increasing demand to achieve significant weight reduction by maintaining the performance levels. Additiona...

Study on Optimization of Automobile Crash Box Considering the Influence of Strain Rate

Abstract: The strain rate is one of the main factors that determines the yield strength of the material, which has a great influence on the accuracy of the numerical simulation of the automobile crash box. The numerical simulation of the crash box considering the strain rate of the material is carried out, and found that the impact force on the longitudinal beam of the car body is large and the energy absorption ability is small during the collision process. Through two sets of optimization studies, the results show that increasing the double-sided convex groove at the proper position of the front crash box can effectively reduce the impact force transmitted to the car body at the initial stage of the collision, and at the same time reduce the energy absorption ability of the crash box; Adding double-sided grooves at the front crash box can make the crash box collapse smoothly, cut down the collision force transmitted to the car body, and increase the energy-absorbing ability. At the same time, the results of the two optimization designs are verified by the methods: the sense of crushing deformation and the average square of all nodes velocity.

Numerical simulation of the crush behavior of tapered tubes

Abstract: Traffic accidents are increasing as a result of an increasing number of vehicles and population growth in recent years. Active and passive safety systems are used in the vehicles we use to...

Gradually collapsible crash boxes with bonded aluminium tubes

Abstract: In this study, a novel crash box idea was presented, including a step-by-step collapsible structure by joining coaxial tubes with gradual bonding surface areas. This telescopic crash box absorbed i...

Evaluation of Energy Absorbing Capacity of Crash Box Filled with Honeycomb Material

Abstract: In this paper, the crush behaviour, crushing efficiency, absolute energy absorption, specific energy absorption and peak load of rectangular tubes made of aluminium alloy 6063 of Paper honeycomb filled and aluminium honeycomb filled subjected to quasi-static compressive loading have been numerically and experimentally investigated. Effect of changing the filler material inside the tube on the specific energy absorption characteristics has been evaluated. Model parameters were determined from quasi-static compression test on paper honeycomb and aluminium honeycomb structure. Peak load carrying capacity, mean crush force capacity of aluminium honeycomb filled aluminium alloy 6063 boxes was higher. Specific energy absorption of paper honeycomb crash box was higher than aluminium honeycomb crash box. The experiments regarding crushing behaviour of crash boxes were conducted on compression test machine whereas numerical simulation was performed through commercially available finite element analysis solver LS-DYNA 971. With the addition of softer filler material increase in energy absorption capacity was observed which is useful in crashworthiness application.

Numerical Analysis of Double-Hat Multi-Corner Column Under Axial Loading

Abstract: Vehicle safety is an essential parameter in vehicle manufacturing. System absorber is required to absorb kinetic energy during the crash to avoid excessive structure damage and injury to passengers. Energy absorber technology was developed in various designs. The crash box is one of the energy absorber components. In the past, the ability to absorb impact energy was increased by thickening wall thickness and increasing wall density. Nowadays, the energy absorbing capacity could be gained by increasing the number of corners in a crash box. In this paper, the numerical analysis of the double-hat multi-corner column was conducted by using LS-DYNA software. Several different spot-weld pitch variations in the double-hat multi-corner column have been studied to obtain sufficient distance between spot-weld. Further, the crushing response of the double-hat multi-corner column then compared with a square column, a square double-hat column, a multi-corner column with 12 corners, and a multi-corner column with 20 corners. The result shows that the double-hat multi-corner column with a narrow spot-weld pitch has better energy absorption capacity. It is also observed that the column with a larger number of corners has more capability to absorb energy.

Optimasi Parameter Desain Multi-Cell Hexagonal Crash Box terhadap Absorbsi Energy Impact dengan Metode Taguchi

Abstract: The crash box is a passive safety system placed between the bumper and the mainframe of the car that functions as an energy absorber to reduce the impact of driving accidents. The purpose of this study is to determine the optimal level of factors and analyze the factors that provide the most significant effect on energy absorption in a multi-cell hexagonal crash box. Identification of parameters that affect the crash box in energy absorption, namely: the position of placement hole (P), the distance of position hole (L), the thickness of crash box (t), and the hole diameter (D). The modeling method has used the design of the crash box by utilizing a computer simulation with software ANSYS 17.0. This research uses aluminum material type AA 6061-T4 and impactor material uses structural steel. Modeling loading using the frontal crash test method. In this modeling, the impactor with a speed of 7.67 m/s with a deformation length of 100 mm. This research uses the experimental design of the Taguchi method with the L 27 orthogonal array. The optimization result were obtained optimum design parameter multi-cell hexagonal crash box with parameter settings P = inner wall; L = 112.5 mm; t = 2 mm, and D = 6.6 mm. Based on the calculated F value ≥ F Table, the factors P, t, and D affect the ability to absorb energy. Thickness crash box (t) has the highest contribution of 98.10% in increasing the value of energy absorption.

An internal crash box

Abstract: The present invention relates to an internal crash box (1), which reduces the effect of the collision on the life cabin and prevents the vehicle body from being permanently damaged in low speed accidents by absorbing the shock effect created by the crash in vehicular accidents, characterized by at least one crash box (C) which is placed on the vehicle chassis and at least one crash traverse (2) which is placed on the crash box (C), at least one first crash box (3) which is placed on the crash traverse (2), at least one groove (31) which is in form of a channel made on the surfaces of the first crash box (3), at least one second crash box (4) which is placed inside the first crash box (3).

M-shaped crash box structure for an automobile front end and assembly thereof

Abstract: An M-shaped crash box structure (100) for an automobile front end and an assembly thereof are provided. The M-shaped crash box structure (100) is of a form that has an M-shaped cross section, and comprises: a first protruding part (10) and a second protruding part (20) extending and protruding towards the +X direction of the automobile, and a depressed part (30) located between the first protruding part (10) and the second protruding part (20). The first protruding part (10) extends in the Z direction of the automobile above the second protruding part (20) and spaced apart from the second protruding part (20). The above-mentioned M-shaped crash box structure is structurally stable and more efficient in energy absorption, and in the meanwhile possesses a certain degree of self-recovery. In addition, the assembly comprising the M-shaped crash box structure is provided.

Optimization of two segments crash box with rubber joint using response surface methodology

Abstract: The development of the crash box as a passive safety device has been carried out. Based on previous studies, it was known that the two segments crash box had the highest energy absorption compared to the one segment crash box. This study aims to determine the effect and the optimum condition of design parameters to specific energy absorption (SEA) on two segments crash box. This study is carried out using a finite element software with optimization methods using response surface methodology. The design parameters used are a segment diameter (D), upper segment thickness (Ta), lower segment thickness (Tb), and connection location (L) of two segments crash box with each parameter consisting of 3 levels. Crash box testing refers to the drop mass test. The impactor with 103 kg mass drop the crash box with speed of 7.67 m/s. The results showed that the specific energy absorption was decreased with larger segment diameter and the lower segment. The lower segment thickness has the most significant effect on the specific energy absorption. The smaller specific energy absorption was occurred for Ta ≤ Tb, and the greater specific energy absorption for Ta > Tb. The optimum two segments crash box is denoted for design parameters: D = 70 mm, Ta = 2.5 mm, Tb = 2.5 mm, and L = 30 mm which has the specific energy absorption of 32,266.47 J/kg and force reaction of 100,905.24 N.

Bumper beam system for automobile

Abstract: The present invention provides a vehicle bumper beam system including: a bumper beam which includes a first crash box unit and a beam unit and is integrally injected; and an energy absorber which is coupled to the bumper beam and has second crash box parts provided with a reinforcing member and a spacer formed between the second crash box parts on both sides

Crash box for vehicles

Abstract: A vehicle crash box is disclosed. According to an embodiment of the present invention, the vehicle crash box is bonded to both sides of a rear bumper beam and connects the bumper beam and a side member. A first plate and a second plate, which are bent in multiple stages, form a coupling member having a front side and a rear side horizontally formed, while forming a closed section at the center by being coupled to each other through a cutting line formed symmetrically on each cross section. The horizontally formed surfaces of the plurality of coupling members are interconnected to each other by welding to be joined to both sides at the rear of the bumper beam.

Impact damping crash box guiding torsion action

Abstract: A crash box (10) placed in front and rear bumper areas of vehicles and folding during crash and providing energy damping and occurrence of torsion together with buckling and thus enhancing energy damping characterized by comprising; a N area (12) formed in lattice structure between a upper surface (C) and a lower surface (D) of the crash box (10), a M area (11) formed in a manner to have less intensity or more intensity in comparison to the N area (12)

6005A aluminum alloy for automobiles and crash box processing method

Abstract: The invention discloses a 6005A aluminum alloy for automobiles and a crash box processing method. The 6005A aluminum alloy for automobiles comprises the following components in percentage by weight: 0.75-0.80% of Si, 0.15-0.20% of Fe, less than or equal to 0.10% of Cu, 0.28-0.30% of Mn, 0.63-0.68% of Mg, 0.06-0.10% of Cr, less than or equal to 0.10% of Zn, less than or equal to 0.10% of Ti and thebalance of Al. The crash box processing method adopts the aluminum alloy. the aluminum alloy is capable of weakening the segregation, at crystal boundaries, of surplus Si, so that embrittlement is not easy to cause and alloy materials are not easy to craze during compression degeneration. The 6005A aluminum alloy crash box prepared by the process satisfies the conditions that the tensile strengthRm is greater than or equal to 280 MPa, the yield strength RP0.2 is greater than or equal to 260 MPa and the elongation percentage A is greater than or equal to 10%; and the crash box is symmetric, uniform in deformation and free of craze at folds during compression degeneration.

Automobile crash box system

Abstract: he invention is related to a crash box system comprising "V" shaped leaf springs (2) located between the front plate (1) and the rear plate (3), wherein the leaf springs (2) have been placed vertical to the front plate (1) and rear plate (3) at the wing corners. Moreover, the system subject to the invention is related to a crash box system comprising a cylindrical bevelled tube (8) placed inside the outer tube (4) having an unconventional structure. The "V" shaped leaf springs (2), an outer crash box (outer tube) (4) having an unconventional structure, the re-entrant hexagonal bottom imperfections (12) and the re-entrant hexagonal top imperfections (13), a cylindrical tube (8) and cylindrical tube trigger mechanism (11) provided in the system subject to invention, enables energy absorption such that the peak forces are kept low at different times. By this means it is aimed to prevent, injuries and traumas that occur due to accident effects such as the whiplash effect during accidents at different speeds.

Vehicle crash box and assembly method of the same

Abstract: A crash box for a vehicle and a method for assembling the same are disclosed According to an embodiment of the present invention, the crash box for a vehicle installed on both sides of the rear of a bumper beam includes: a mounting plate which has a first slot and a second slot of a predetermined length in a vertical direction on both sides parallel to each other with respect to the center; and a box unit in which a first panel and a second panel form a box shape and a box space by overlapping each other, wherein flanges are formed at one end of the box unit, respectively, to be inserted and stuck into the first slot and the second slot of the mounting plate and coupled to each other

Ultralight front end module with lower memberless

Abstract: An ultralight front end module with lower memberless may include a carrier, a crash box inserted into a lateral direction on one side surface of the carrier, a mounting portion fixedly fastened to the crash box and fixedly mounted on the one side surface of the carrier, and a front back beam fixedly coupled to an end portion of the crash box.