Enhancing Crashworthiness through the Design Modification of a Grooved Aluminium Crash Box with Screw and Sleeve for Improved Energy Absorption
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Abstract
Crash boxes are an important safety feature in vehicles. They help to protect occupants from injury by absorbing the energy of an impact. This research delves into the nuanced examination of the structural dynamics and crashworthiness of aluminium crash boxes, with a specific focus on the introduction of strategically positioned vertical grooves with screw fitted in sleeve. The study aims to comprehensively analyse the effects of these grooves on the energy absorption capabilities and structural response of aluminium crash boxes during impact collisions. Utilizing advanced numerical simulations based on finite element analysis, it will systematically be investigating the dynamic behaviour of crash box structures, comparing scenarios with and without integrated vertical grooves under variation of impact velocity. The vertical grooves help to distribute the force of the impact more evenly, which prevents the crash box from collapsing. The grooves function as structural enhancements, augmenting the crashworthiness of the aluminium component while preserving its lightweight attributes. The crash box is fabricated and tested in a drop impact test rig under certain conditions and validated with the simulation result. The study addresses intricacies associated with groove design, encompassing manufacturability considerations and structural complexities. This research contributes valuable insights to the ongoing discourse on optimizing vehicle safety through innovative crash box design strategies. The outcomes are poised to inform future advancements in automotive engineering, providing a technical foundation for manufacturers, designers and researchers to navigate the intricate trade-offs between structural integrity, energy absorption efficiency and manufacturing feasibility in the realm of aluminium crash box development.
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