The prediction of energy-absorption on the car crush box

This paper describes a computationally aided design process of a thin-walled structure of a retail car crash box subjected to a progressive crashing in longitudinal axial direction. The study was broken up into three phases: (1) digitising of the existing retail car crash box structure, (2) the crash simulation of the structure using dynamic explicit formulation (3) the verification of the simulation of the accident. In the digitalization phase of this structure, the perimeter of the cross section, the shape, the length and the thickness of profile were made the same as the Original Equipment Manufacturer (OEM) the product of a compact car found in the local market. The crashing procedure and parameter follow the New Car Assessment Program (NCAP) by National Highway Traffic Safety Administration (NHTSA). It found that the value of energy absorbed by the crash box was 5.91 KJ. The specific energy absorption is 21.53 KJ/kg. The crash force efficiency is 0.54. The simulation method, that was verified using square tube structure, resulting in the value that matches to the current simulation done by another researcher.