Research on the crashworthiness of a novel crush box with corrugated structures

doi:10.3969/j.issn.1674-8484.2022.03.006

Abstract

Abstract:

A novel crush box with corrugated structures was designed and its crashworthiness was investigated to improve the passive safety of vehicles. A finite element model was established to compare the deformation modes and energy absorption properties of the equidistant continuous corrugated tube with that of the equidistant discrete corrugated tube with different corrugated shapes. It was conducted that the multi-objective optimization on the parameters of corrugated shape and the thickness of equidistant continuous corrugated tube. The results show that the equidistant continuous corrugated tube deforms stably under axial compression when the number of corrugations is greater than or equal to 8. Compared with the equidistant discrete tube, the specific energy absorption remains basically unchanged, and the initial peak crush force is reduced by 14.31%, showing that the equidistant continuous corrugated crush box has better energy absorption characteristics than the traditional equidistant discrete corrugated crush box, and it has important application value in the field of improving the passive safety of vehicles.

Key words: passive safety, crashworthiness, crush box, corrugated structure, multi-objective optimization

CLC Number:

U463.83

LUO Geng, ZHAO Jiannan, CHEN Liang, CHAI Chengpeng, WANG Tong, CHEN Yisong. Research on the crashworthiness of a novel crush box with corrugated structures[J]. Journal of Automotive Safety and Energy, 2022, 13(3): 453-462.

Figures/Tables 26

References 23

[1]	Ebrahimi S, Vahdatazad N. Multiobjective optimization and sensitivity analysis of honeycomb sandwich cylindrical columns under axial crushing loads[J]. Thin-Walled Structures, 2015, 88(3): 90-104. doi: 10.1016/j.tws.2014.12.004 URL
[2]	赵曦, 陈帅, 盈亮. 梯度强度汽车薄壁结构抗撞性优化[J]. 汽车工程, 2018, 40(5): 7.
	ZHAO Xi, CHEN Shuai, YIN Liang. Crashworthiness optimization of automotive thin-walled structure with functionally graded strength[J]. Autom Engineering, 2018, 40(5): 7. (in Chinese)
[3]	贺良国, 赵杰, 谷先广. 基于多胞结构的车身前端轻量化和耐撞性设计[J]. 汽车工程, 2020, 42 (6): 832-839.
	HE Liangguo, ZHAO Jie, GU Xianguang. Lightweight and crashworthiness design of vehicle bodyfront-end based on multi-cell structure[J]. Autom Engineering, 2020, 42(6): 832-839. (in Chinese)
[4]	霍鹏, 许述财, 范晓文, 等. 鹿角骨单位仿生薄壁管斜向冲击耐撞性研究[J]. 爆炸与冲击, 2020, 40(11): 127-138.
	HUO Peng, XU Shucai, FAN Xiaowen, et al. Oblique impact resistance of a bionic thin-walled tube based on antles osteon[J]. Expl Shock Wave, 2020, 40(11): 127-138. (in Chinese)
[5]	杨欣, 范晓文, 许述财. 仿虾螯结构薄壁管设计及耐撞性分析[J]. 爆炸与冲击, 2020, 40(4): 62-72.
	YANG Xin, FAN Xiaowen, XU Shucai, et al. Design and crashworthiness analysis of thin-walled tubes based on a shrimp chela structure[J]. Expl Shock Wave, 2020, 40(4): 62-72. (in Chinese)
[6]	El-hage H, Mallick P K, Zamani N. A numerical study on the quasi-static axial crush characteristics of square aluminum tubes with chamfering and other triggering mechanisms[J]. Int’l J Crashworthiness, 2005, 10(2): 183-96.
[7]	Singace A, El-sobky H. Behaviour of axially crushed corrugated tubes[J]. Int’l J Mech Sci, 1997, 39(3): 249-68.
[8]	Chen D H, Ozaki S. Numerical study of axially crushed cylindrical tubes with corrugated surface[J]. Thin-Walled Structures, 2009, 47(11): 87-96.
[9]	WU Shengyin, LI Guangyao, SUN Guangyong, et al. Crashworthiness analysis and optimization of sinusoidal corrugation tube[J]. Thin-Walled Structures, 2016(105): 121-134.
[10]	Takuma I, Tadahiro S, Kazumi M, et al. Curvature sensitive analysis of axially compressed cylindrical tubes with corrugated surface using isogeometric analysis and experiment[J]. Comput Aided Geom Desig, 2016(49): 17-30.
[11]	Nalla Mohamed M. An insight to improve crushing energy absorption capacity of cylindrical tubes using corrugation under axial compression loading[J]. Mater Today: Proceed, 2022(62): 799-805.
[12]	刘尧庆. TRB波纹管结构参数对碰撞吸能的影响[J]. 内燃机与配件, 2022(4): 20-23.
	LIU Yaoqing. Influence of TRB Bellows Structural Parameters on Impact Energy Absorption[J]. Int’l Combust Engi Parts, 2022(4): 2023-3. (in Chinese)
[13]	LI Zhixiang, MA Wen, YAO Shuguang, et al. Crashworthiness performance of corrugation- reinforced multicell tubular structures[J]. Int’l J Mech Sci, 2021 (190): 106038.
[14]	DENG Xiaolin, QIN Shangan, HUANG Jiale, Energy absorption characteristics of axially varying thickness lateral corrugated tubes under axial impact loading[J]. Thin-Walled Structures, 2021(163): 107721.
[15]	尹华伟, 王陈凌, 段金曦, 等. 新型薄壁管耐撞性分析及优化设计[J]. 高压物理学报, 2021, 35 (3): 100-110.
	YIN Huawei, WANG Chenling, DUAN Jinxi, et al. Crashworthiness analysis and optimization design of new thin-walled tube[J]. Chin J High Press Phys, 2021, 35(3): 100-110. (in Chinese)
[16]	邓小林, 黄家乐. 轴向变厚度星形管吸能特征及多目标优化研究[J]. 振动与冲击, 2022, 41(8): 287-296.
	DENG Xiaolin, HUANG Jiale. A study on energy absorption characteristics and multi-objective optimization of an axial variable thickness star-shaped tube[J]. Expl Shock Wave, 2022, 41(8): 287-296. (in Chinese)
[17]	Alkhatib S E, Tarlochan F, Eyvazian A. Collapse behavior of thin-walled corrugated tapered tubes[J]. Engi Struct, 2017(150): 674-692.
[18]	Rawat S, Narayanan A, Upadhyay A K, et al. Multiobjective optimization of functionally corrugated tubes for improved crashworthiness under axial Impact[J]. Procedia Engineering, 2017(173): 1382-1389.
[19]	Agrawal D, Rawat S, Upadhyay A K. Crashworthiness of circular tubes with structurally graded corrugations[C]// Int’l Mobil Conf, SAE Tech Papers, MNNIT Allahabad, India, 2016.
[20]	YAO Shuguang, HUO Yanfei, YAN Kaibo, et al. Crashworthiness study on circular hybrid corrugated tubes under axial impacts[J]. Thin-Walled Structures, 2019(145): 1-12.
[21]	余同希. 能量吸收: 结构与材料的力学行为和塑性分析[M]. 北京: 科学出版社: 2019: 148-149.
	YU Tongxi. Energy Absorption: Mechanical Behavior and Plasticity Analysis of Structures and Materials[M]. Beijing: Science Press, 2019: 148-149. (in Chinese)
[22]	MA Wen, LI Zhixiang, XIE Suchao. Crashworthiness analysis of thin-walled bio-inspired multi-cell corrugated tubes under quasi-static axial loading[J]. Engineering Structures, 2020(204): 110069.
[23]	Deb K, Agrawal S, Pratap A, et al. A fast elitist non-dominated sorting genetic algorithm for multi-objective optimization: NSGA-II[C]// Lecture Notes in Computer Science, Kanpur, India: Springer Verlag, 2000.

密度, ρ	2 700 kg / m³
弹性模量, E	73.32 GPa
泊松比, μ	0.3
屈服应力, σ_y	66.41 MPa
极限拉应力, σ_u	158.75 MPa
应变硬化指数, n	0.174 6

密度, ρ	2 700 kg / m³
弹性模量, E	73.32 GPa
泊松比, μ	0.3
屈服应力, σ_y	66.41 MPa
极限拉应力, σ_u	158.75 MPa
应变硬化指数, n	0.174 6

	IPCF kN	E_A J	SEA kJ·kg^-1	MCF kN	CFE%	ULC
实验值	9.86	602.24	5.47	6.69	69	0.08
仿真值	9.93	605.95	5.51	6.73	68	0.08
误差 / %	0.71	0.61	0.71	0.64	1.8	4.31

	IPCF kN	E_A J	SEA kJ·kg^-1	MCF kN	CFE%	ULC
实验值	9.86	602.24	5.47	6.69	69	0.08
仿真值	9.93	605.95	5.51	6.73	68	0.08
误差 / %	0.71	0.61	0.71	0.64	1.8	4.31

H mm	IPCF kN	E_A J	SEA kJ·kg^-1	MCF kN	CFE	ULC
0.5	0.899 63	50.232 88	1.947 01	0.837 21	0.930 62	0.865 11
1.0	3.062 75	179.721 30	3.476 23	2.995 36	0.978.00	0.094 27
1.5	6.623 35	406.772 20	5.248 67	6.779 54	1.023 58	0.772 61
2.0	11.652 80	758.608 50	7.365 13	12.643 47	1.085 02	0.878 22