Development of multi aluminium foam-filled crash box systems to improve crashworthiness performance of road Service vehicle

• Published in: European journal of mechanics, A, Solids A, Solids, 2025-01, Vol.109, p.105433, Article 105433
• Main Authors: De Biasio, A., Ghasemnejad, H., Srimanosaowapak, S., Watson, J.W.
• Format: Article
• Language: English
• Subjects: Aluminium foam; Crashworthiness; Honeycomb; Impact; Stiffener reinforcements
• ISSN: 0997-7538
• DOI: 10.1016/j.euromechsol.2024.105433

Honeycomb crash absorbers are known as mechanical energy-absorbing systems in both automotive and aerospace industries. However, the gap of knowledge in the transverse impacts of multi-foam-filled or stiffener-reinforced honeycombs is still unfilled. This paper investigates the energy absorption process in large crash boxes applied onto a road maintenance vehicle, exploring four aluminium honeycomb absorbers with design factors like added aluminium foam, corrugated sheet thicknesses, and stiffener reinforcements. The optimised foam-filled honeycomb structures are analysed for four crash scenarios in two different directions; frontal impact (T-direction) and lateral impact (L-direction) subjected to 50 km/h crash speed. The objective of this research is to identify the most efficient design that achieves a maximum acceleration of up to 20g while absorbing a specific energy of 145 kJ. The FE models were developed in ABAQUS to explore various scenarios related to damage zones, impact energy capabilities, and multi-foam-filled crash boxes. Finally, the lightest design of honeycomb absorbers which can maximise energy absorption while maintaining acceleration below the specified threshold of 20g will be recommended. •This paper investigates energy absorption in large crush boxes on a road maintenance vehicle, exploring four aluminium honeycomb cases with various design factors.•The ABAQUS software was used for the FE model development, exploring scenarios related to crushed area, impact energy, and number of crash boxes.•The main goal of this study is to define the lightest design of honeycomb absorbers maximising energy absorption while maintaining acceleration below 20g for safety requirements.