Active adaptive energy dissipation systems can receive and interpret data from onboard vehicle sensors to respond to external stimuli by modifying their geometries and corresponding load bearing capacities. This is a highly promising subfield in structural crashworthiness since these devices possess multiple potential configurations, thus allowing them to achieve the preferred balance between high-capacity energy absorption and mitigation of human injury for a broad and disparate range of loading conditions. A novel cutting-based active adaptive energy absorber was conceptualized, design and theoretically assessed in this investigation with guidance from previous experimental observations and extensively validated modeling approaches. The proposed, hydraulically-driven active adaptive cutter (HAAC) was capable of transitioning between 4, 6, 8 and 12-bladed cutting deformation modes in either direction (e.g., from 6 to 12-bladed cutting or vice versa) and in a nondestructive manner. The steady-state force capacity could be varied by an average factor of 2.6, quantifying the significant range available to the HAAC regardless of extrusion material or geometry. A broad scale analytical study revealed that the proposed HAAC could eclipse the energy absorbing performance of the traditional axial crushing deformation mode for AA6061-T6 extrusions with 50.80 mm to 76.20 mm diameters and 1.59 mm to 3.18 mm wall thicknesses, with an average enhancement of 73 % calculated for the 12-bladed cutting mode. The newly proposed active adaptive capabilities allow the system to carefully balance energy absorption requirements and mitigation of occupant/pedestrian injury in a manner which the current state-of-the-art cannot achieve.
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