In recent years, the rise in road accidents an‎d the necessity of improving vehicle safety have drawn researchers’ attention toward the design of high energy-absorbing structures. The crash box is considered one of the key components of a vehicle’s safety system, responsible for absorbing the energy generated during collisions. In this study, the mechanical behavior of cellular structures is investigated with the aim of enhancing the energy absorption performance of crash boxes. Numerical modeling of both the crash box an‎d various cellular structures was conducted separately using Abaqus software. After identifying the most efficient cellular structure for use within the crash box, the selec‎ted structure was embedded inside the crash box, an‎d key parameters such as absorbed energy, peak initial force, an‎d structural deformation were eva‎luated. Among the analyzed structures—which include hexagonal, re-entrant, aperiodic, ESI, STH, an‎d BCC geometries—the STH structure, which combines triangular an‎d star-shaped cells, demonstrated the best performance. This structure exhibits a two-stage plastic deformation behavior: initially, the star-shaped cells compress under low stress, followed by the activation of triangular cells capable of withstan‎ding higher stress levels. This characteristic leads to a reduction in the peak initial force an‎d an increase in energy absorption, making it highly desirable for optimal crash box performance. Furthermore, the effect of specific density was investigated at values of 0.1, 0.2, 0.3, an‎d 0.4, an‎d the results showed that despite a slight change in the maximum initial force, the force efficiency increased by 178, 661, 1622, an‎d 2955 percent, respectively, compared to the empty crash box.

محمد سيلاني

محمد مشايخي , محمدرضا فروزان