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.