Numerical simulation of crashworthiness parameters for design optimization of an automotive crash-box

Automotive manufacturers rely on rigorous testing and simulations to construct their vehicles durable and safe in all aspects. One such vital factor is crash safety, otherwise known as crashworthiness. Crash tests are conventional forms of non-destructive methods to validate the vehicle for its crashworthiness and compatibility based on different operating conditions. The frontal impact test is the most primary form of crash test, which focuses on improving passenger's safety and comfort. According to NHTSA, a vehicle is rated based on these safety criteria, for which automobile manufacturers conduct a plethora of crash-related studies. Numerical simulation aids them in cutting down testing time and overall cost endured by providing a reliable amount of insights into the process. The current study is aimed at improving the crashworthiness of a crash box in a lightweight passenger car, such that it becomes more energy absorbent in terms of frontal impacts. All necessary parameters such as energy absorption, mean crush force, specific energy absorption, crush force efficiencies are evaluated based on analytical and finite element methods. There was a decent agreement between the analytical and simulation results, with an accuracy of 97%. The crashworthiness of the crash box was improved with the help of DOE-based response surface methodology (RSM). The RSM approach helped in improving the design of the crash box with enhanced EA & CFE by 30% and 8.8% respectively. The investigation of design variables on the energy absorption capacity of the thin-walled structure was also done. For the axial impact simulations, finite element solver Virtual Performance Solution − Pam Crash from the ESI group is used.