A review on crashworthiness studies of crash box structure

Abstract Many studies have focused on the topic of vehicle safety, including the study on crashworthiness. In vehicle, a crash box structure is an integral component for ensuring the safety of a car. It serves as an energy-absorbing member, together with the front bumper in case of frontal collision during car accidents. Therefore, special attention has to be given towards this structure in order to have better understanding regarding its mechanism of deformation and absorbing kinetic energy from the collision, as well as on how to obtain good crashworthy properties from this structure. This study, primarily, is based on extensive literature survey pertaining to the topic of crash box. As the topic of energy-absorbing member in a car is extensive, this review solely focuses on crash box structure. The main motivation of this paper is to summarise the different approaches and aspects of researches performed on car crash box structure to gain comprehensive knowledge regarding the study on crash box.

[1]  Yuanming Xu,et al.  Improvement of crash energy absorption of 2D braided composite tubes through an innovative chamfer external triggers , 2018 .

[2]  Srinivasa Prakash Regalla,et al.  Comparative Study of Trigger Configuration for Enhancement of Crashworthiness of Automobile Crash Box Subjected to Axial Impact Loading , 2017 .

[3]  Tomasz Wierzbicki,et al.  THE CONCEPT OF DOUBLE-WALLED SANDWICH COLUMNS FOR ENERGY ABSORPTION , 1999 .

[4]  Zheng-Dong Ma,et al.  Dynamic crushing of double-arrowed auxetic structure under impact loading , 2018, Materials & Design.

[5]  D. Xiao,et al.  Impact energy absorption performances of ordinary and hierarchical chiral structures , 2019, Thin-Walled Structures.

[6]  Johan Kolstø Sønstabø,et al.  Static and dynamic testing and modelling of aluminium joints with flow-drill screw connections , 2018 .

[7]  Tao Liu,et al.  Static and dynamic crushing of novel porous crochet-sintered metal and its filled composite tube , 2019, Composite Structures.

[8]  Hongwei Song,et al.  Axial impact behavior and energy absorption efficiency of composite wrapped metal tubes , 2000 .

[9]  Gang Zheng,et al.  Design for cost performance of crashworthy structures made of high strength steel , 2019, Thin-Walled Structures.

[10]  Hui Zhang,et al.  Axial crushing of tapered circular tubes with graded thickness , 2015 .

[11]  Sadjad Pirmohammad,et al.  Crushing behavior of new designed multi-cell members subjected to axial and oblique quasi-static loads , 2016 .

[12]  T. Børvik,et al.  Quasi-static behaviour of crash components with steel skins and polymer foam cores , 2018, Materials Today Communications.

[13]  Abdul-Ghani Olabi,et al.  On the crashworthiness performance of thin-walled energy absorbers: Recent advances and future developments , 2017 .

[14]  Feng Zhu,et al.  A novel principal components analysis (PCA) method for energy absorbing structural design enhanced by data mining , 2019, Adv. Eng. Softw..

[15]  G. Belingardi,et al.  A crashworthy problem on composite structures using a mathematical approach , 2014 .

[16]  P. Jonsén,et al.  Influence of microstructure on the fracture toughness of hot stamped boron steel , 2019, Materials Science and Engineering: A.

[17]  Jin Wang,et al.  Crashworthiness design of novel hierarchical hexagonal columns , 2018, Composite Structures.

[18]  Yugang Duan,et al.  Effect of tailored plies on the energy absorption capability of square CFRP tubes with discontinuous fibers , 2019, Composite Structures.

[19]  P. Hao,et al.  The energy absorption of rectangular and slotted windowed tubes under axial crushing , 2018, International Journal of Mechanical Sciences.

[21]  Zheng-Dong Ma,et al.  Crashworthiness analysis of double-arrowed auxetic structure under axial impact loading , 2019, Materials & Design.

[22]  Guan Zhou,et al.  Structure design and multi-objective optimization of a novel crash box based on biomimetic structure , 2018 .

[23]  A. Rahi.  Controlling energy absorption capacity of combined bitubular tubes under axial loading , 2018 .

[24]  Hai Wang,et al.  Energy absorption behaviors of pre-folded composite tubes with the full-diamond origami patterns , 2019, Composite Structures.

[25]  D. Casellas,et al.  On the correlation between fracture toughness and crash resistance of advanced high strength steels , 2019, Engineering Fracture Mechanics.

[26]  Qiang Liu,et al.  Quasi-static axial crushing and transverse bending of double hat shaped CFRP tubes , 2014 .

[27]  Jianguang Fang,et al.  Crashworthiness design for foam-filled thin-walled structures with functionally lateral graded thickness sheets , 2015 .

[28]  S. Polak,et al.  Energy absorption of thin-walled profiles made of AZ31 magnesium alloy , 2018 .

[29]  H. Ravi Sankar,et al.  Effect of circular perforations on the progressive collapse of circular cylinders under axial impact , 2018, International Journal of Impact Engineering.

[30]  Mohammad Jawaid,et al.  Design and materials development of automotive crash box: a review , 2017 .

[31]  Ying Li,et al.  Development of high-performance energy absorption component based on the structural design and nanocrystallization , 2018 .

[32]  Zheng-Dong Ma,et al.  Multi-objective crashworthiness optimization for an auxetic cylindrical structure under axial impact loading , 2018 .

[33]  K. Annamalai,et al.  Crushing response of square aluminium column filled with carbon fibre tubes and aluminium honeycomb , 2018, Thin-Walled Structures.

[34]  F. Samer,et al.  IMPROVEMENT OF ENERGY ABSORPTION OF THIN WALLED HEXAGONAL TUBE MADE OF MAGNESIUM ALLOY BY USING TRIGGER MECHANISMS , 2013 .

[35]  A. Jusuf,et al.  Crashworthiness analysis of foam–filled square column considering strain rate effect of the foam , 2018, Thin-Walled Structures.

[36]  H. Ghasemnejad,et al.  Lightweight design to improve crushing behaviour of multi-stitched composite tubular structures under impact loading , 2019, Thin-Walled Structures.

[37]  Odd Sture Hopperstad,et al.  Design of aluminium foam-filled crash boxes of square and circular cross-sections , 2001 .

[38]  Tatacipta Dirgantara,et al.  The Effects of Spot Weld Pitch to the Axial Crushing Characteristics of Top-Hat Crash Box , 2014 .

[39]  H. Zarei,et al.  Optimum honeycomb filled crash absorber design , 2008 .

[40]  Ibrahim Kutay Yilmazcoban,et al.  Numerical and experimental approach of various sectioned new concept of the crash-boxes to determine the reliability and crashworthiness of the vehicles during frontal impacts , 2019, Sakarya University Journal of Science.

[41]  Qing Li,et al.  Crashing analysis and multiobjective optimization for thin-walled structures with functionally graded thickness , 2014 .

[43]  Saeed Ziaei-Rad,et al.  Parametric study and numerical analysis of empty and foam-filled thin-walled tubes under static and dynamic loadings , 2008 .

[44]  Mojtaba Sadighi,et al.  A study on the static and dynamic loading of the foam filled metal hexagonal honeycomb – Theoretical and experimental , 2011 .

[45]  Z. You,et al.  Quasi-static impact of origami crash boxes with various profiles , 2019, Thin-Walled Structures.

[46]  O. Mohammadiha,et al.  Crush behavior optimization of multi-tubes filled by functionally graded foam , 2016 .

[47]  Eko Siswanto,et al.  CRASH ENERGY ABSORPTION OF MULTI-SEGMENTS CRASH BOX UNDER FRONTAL LOAD , 2016 .

[48]  Song Yao,et al.  On folding mechanics of multi-cell thin-walled square tubes , 2018 .

[49]  Mohamed Zahran,et al.  A novel tailor-made technique for enhancing the crashworthiness by multi-stage tubular square tubes , 2018 .

[50]  G. Hirt,et al.  Enhancing the crashworthiness of high-manganese steel by strain-hardening engineering, and tailored folding by local heat-treatment , 2016 .

[51]  J. Aurrekoetxea,et al.  Design and characterisation of cellular composite structures for automotive crash-boxes manufactured by out of die ultraviolet cured pultrusion , 2019, Composites Part B: Engineering.

[52]  Guan Zhou,et al.  Analysis and parametric optimization of a novel sandwich panel with double-V auxetic structure core under air blast loading , 2018, International Journal of Mechanical Sciences.

[53]  Nawawi Chouw,et al.  Crashworthiness characteristics of flax fibre reinforced epoxy tubes for energy absorption application , 2013 .

[54]  Cenk Kılıçaslan,et al.  Numerical crushing analysis of aluminum foam-filled corrugated single- and double-circular tubes subjected to axial impact loading , 2015 .

[55]  G. Belingardi,et al.  Axial crushing of metal-composite hybrid tubes: experimental analysis , 2018 .

[56]  Pawel Woelke,et al.  Ship Impact Study: Analytical Approaches and Finite Element Modeling , 2012 .

[57]  A. Hamouda,et al.  Design of thin wall structures for energy absorption applications: Enhancement of crashworthiness due to axial and oblique impact forces , 2013 .

[58]  Jianguang Fang,et al.  Dynamic impact response of aluminum honeycombs filled with Expanded Polypropylene foam , 2019, Composites Part B: Engineering.

[59]  Q. Estrada,et al.  Effect of radial clearance and holes as crush initiators on the crashworthiness performance of bi-tubular profiles , 2019, Thin-Walled Structures.

[60]  Meng Zou,et al.  Bionic design and multi-objective optimization for variable wall thickness tube inspired bamboo structures , 2018 .

[61]  K. Pianthong,et al.  Impact Response of Circular Aluminum Tube Filled with Polyurethane Foam , 2014 .

[62]  M. Shojaeefard,et al.  Energy absorption analysis for tapered multi-cell tubes improved by foams: Theoretical development and numerical simulation , 2019, Composite Structures.

[63]  Massimiliano Avalle,et al.  Experimental investigation of the energy absorption capability of continuous joined crash boxes , 2007 .

[64]  Minjie Wang,et al.  Unified parametric modeling of origami-based tube , 2018, Thin-Walled Structures.

[65]  D. Rajak,et al.  Crashworthiness performance and microstructural characteristics of foam-filled thin-walled tubes under diverse strain rate , 2019, Journal of Alloys and Compounds.

[66]  Guangyao Li,et al.  Crushing analysis and multiobjective optimization for functionally graded foam-filled tubes under multiple load cases , 2014 .

[67]  Wenjie Zuo,et al.  Simplified crashworthiness method of automotive frame for conceptual design , 2018, Thin-Walled Structures.

[68]  H Zhao,et al.  Parameter study and multi-objective optimisation of an axisymmetric rectangular tube with diaphragms for subways , 2019, Thin-Walled Structures.

[69]  Hoon Huh,et al.  Effect of auxetic structures on crash behavior of cylindrical tube , 2019, Composite Structures.

[70]  Qing Li,et al.  Design of bionic-bamboo thin-walled structures for energy absorption , 2019, Thin-Walled Structures.

[71]  A. Khalkhali,et al.  Crashworthiness multi-objective optimization of the thin-walled tubes under probabilistic 3D oblique load , 2018, Materials & Design.

[72]  A. Hamouda,et al.  Experimental and theoretical studies on axially crushed corrugated metal tubes , 2018 .

[74]  Dayong Hu,et al.  Effects of fiber orientation and wall thickness on energy absorption characteristics of carbon-reinforced composite tubes under different loading conditions , 2016 .

[75]  Jonas A. Zukas,et al.  Practical Aspects of Numerical Simulations of Dynamic Events: Effects of Meshing. , 2000 .

[76]  Dayong Hu,et al.  Energy-absorption characteristics of a bionic honeycomb tubular nested structure inspired by bamboo under axial crushing , 2019, Composites Part B: Engineering.

[77]  Kjell G. Robbersmyr,et al.  Prediction of Vehicle Crashworthiness Parameters Using Piecewise Lumped Parameters and Finite Element Models , 2018, Designs.

[78]  Weiyuan Guan,et al.  Experimental and numerical investigations of the plastic response and fracturing of an aluminium-plated structure with transition circular arcs subjected to impact loading , 2018, Thin-Walled Structures.

[79]  C. V. Nielsen,et al.  On the Performance of Thin-Walled Crash Boxes Joined by Forming , 2018, Materials.

[80]  A. A. Nia,et al.  Comparative analysis of energy absorption and deformations of thin walled tubes with various section geometries , 2010 .

[81]  H. Kavi,et al.  Predicting energy absorption in a foam-filled thin-walled aluminum tube based on experimentally determined strengthening coefficient , 2006 .

[82]  Bo Wang,et al.  Energy absorption of thin-walled square tubes designed by kirigami approach , 2019, International Journal of Mechanical Sciences.

[83]  Dapeng Qu,et al.  Experimental investigation into dynamic axial impact responses of double hat shaped CFRP tubes , 2015 .

[84]  Siavash Talebi Taher,et al.  Energy absorption and failure response of silk/epoxy composite square tubes: Experimental , 2012 .

[85]  T. Wierzbicki,et al.  Experimental and numerical studies of foam-filled sections , 2000 .

[86]  Xianghua Liu,et al.  Axial crashing analysis for tailor rolled square tubes with axially graded both wall thickness and material strength , 2017 .

[87]  A. Cheng,et al.  Theoretical prediction and crashworthiness optimization of thin-walled structures with single-box multi-cell section under three-point bending loading , 2019, International Journal of Mechanical Sciences.

[88]  S. Polak,et al.  Progressive crushing as a new mechanism of energy absorption. The crushing study of magnesium alloy crash-boxes , 2019, International Journal of Impact Engineering.

[89]  I. Ulacia,et al.  Effect of fibre volume fraction on energy absorption capabilities of E-glass/polyester automotive crash structures , 2016 .

[90]  Murat Altin,et al.  The effect of percent foam fill ratio on the energy absorption capacity of axially compressed thin-walled multi-cell square and circular tubes , 2017 .

[91]  M. W. Joosten,et al.  Effect of environmental conditions on the failure mechanisms and energy absorption of open-section crush elements under quasi-static loading , 2019, Composite Structures.

[92]  He Ning,et al.  Crashworthiness behavior of Koch fractal structures , 2018 .

[93]  Qing Li,et al.  Experimental investigation of the quasi-static axial crushing behavior of filament-wound CFRP and aluminum/CFRP hybrid tubes , 2018, Composite Structures.

[94]  Rafea Dakhil Hussein,et al.  An analytical model of square CFRP tubes subjected to axial compression , 2018, Composites Science and Technology.

[95]  M. Mahbod,et al.  Energy absorption analysis of a novel foam-filled corrugated composite tube under axial and oblique loadings , 2018, Thin-Walled Structures.

[96]  Wanzhong Zhao,et al.  Structure design and multi-objective optimization of a novel NPR bumper system , 2018, Composites Part B: Engineering.

[97]  M. D. Goel.  Deformation, energy absorption and crushing behavior of single-, double- and multi-wall foam filled square and circular tubes , 2015 .

[98]  He Siyuan,et al.  Density gradient tailoring of aluminum foam-filled tube , 2019, Composite Structures.

[99]  Qing Li,et al.  Residual crashworthiness of CFRP structures with pre-impact damage – An experimental and numerical study , 2018, International Journal of Mechanical Sciences.

[100]  Weizhao Gao,et al.  Crushing analysis and crashworthiness optimization of tailor rolled tubes with variation of thickness and material properties , 2018 .

[101]  Daniel Iozsa,et al.  Studies about the Behavior of the Crash Boxes of a Car Body , 2016 .