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
Highlights
The number of vehicles in Indonesia increases every year
The benefit of the study is to develop a crash box design with honeycomb filler and get a design, which results in an increase in energy absorption through computer simulations with reducing the time required in the trial and error setting of the crash box design process
It can be seen that the hexagonal crash box with honeycomb filler has the largest Crash Force Efficiency (CFE) value. This showed that the addition of aluminum honeycomb as a filler for the crash box will increase the amount of CFE
Summary
The number of vehicles in Indonesia increases every year. there is an increase in the number of accidents, which cause fatalities [1]. Accidents on vehicles usually occur in three types of crash, namely the frontal, oblique and roll over where 64 % of the average accidents occur in the frontal direction [2] Based on these conditions, a safety system on the vehicle is required in order to minimize the impact caused by the collision. Safety standard for front impact used is FMVSS 208 in the USA [3], in Canada the standard is CMVSS 208 [4] and in Europe it is ECE R-12 [5] In another test type, the energy absorption response of the crash box under oblique loads becomes a challenge due to bending mode occurring rather than progressive axial crushing. Studies are devoted to improving the energy absorption of the crash box without increasing volume and lightweight, cellular materials such as honeycombs are developed as fillers for the crash box design
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