Optimizing Crash Box Design for Enhanced Vehicle Crashworthiness: A Study on Screw-in-the-Groove Mechanism and Al5052 Material Thickness Variations
Main Article Content
Abstract
This paper delves into the realm of crashworthiness, a critical aspect of vehicle design aimed at enhancing occupant protection and minimizing fatalities and vehicle damage. The study focuses on the force required for a single screw in a crash box, employing a unique screw-in-the-groove mechanism and varying thicknesses of Al5052 material. The investigation utilizes Hypermesh in LS Dyna Profile to simulate low-speed crash scenarios, providing valuable insights into the rupture dynamics. In this research initiative, chosen crash box plates were selected for simulation, exploring and substantiating the innovative concept, specifically focusing on validating the optimized thickness as part of our primary research efforts. The crumple bar assembly incorporates a longitudinally oriented groove situated in the central section of the crash box plate. Within this groove, a latitudinal fixed screw with precise dimensions and locking mechanisms was housed. The simulation parameters are defined with an impact velocity of 15 km/h and a 350 kg mass acting on the screw in the groove of the crash box plates. A meticulously optimized criterion ensures that the screw's travel distance remains below 130mm during the simulation. The model setup includes pre-calculations, pre-simulation for groove stamping, stamp geometry and crash simulation. The Standard Vehicle Testing Procedure was followed in accordance with the Research Council for Automobile Repairs. Results from the simulation for thicknesses of 2, 2.5, 3, 3.5 and 4 mm were systematically analysed. The findings reveal a nuanced relationship between thickness and the performance metrics such as displacement and internal energy absorption.
Article Details
Issue
Section
Articles
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms: a. Authors retain copyright and grant the journal right of first publication, with the work two years after publication simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal. b. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal. c. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work (See The Effect of Open Access).