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<p>Passenger safety during vehicle collision led to the requirements of improved crashworthiness. Most of the previous work is focused on standalone crashworthy structures having limited load adaptability and modularity. To mitigate these drawbacks, a novel metallic nested tube structure is proposed resulting increased energy absorption efficiency and modularity. The proposed energy absorber has fine as well as coarse step tunability to suit real world requirements. This structure comprises of three deformable structures i.e. Skin, Outer tube and Inner tube. Sensitivity analysis is performed to study the effect of skin thickness, outer tube thickness, inner tube thickness and number of inner tubes on energy absorption. Four types of nested structures namely C-1/C-2/C-3/C-4 are obtained by using 1/3/5/7 inner tubes. Numerically estimated MCF for C-1/C-2/C-3/C-4 are 7.85kN/10kN/13kN/18.16kN respectively. Due to highest MCF, C-4 is found to absorb 231%/181%/140% more energy than C-1/C-2/C-3. Multivariable optimization using L16 Taguchi design led to two variants. NTS<sub>4/4/4/4</sub>, containing maximum thickness of all deformable members and 7 inner tubes, is found to absorb highest energy. Whereas, NTS<sub>1/4/4/4</sub> possessing combination of thinnest skin, thickest inner/outer tubes and 7 inner tubes reflected superior specific energy absorption. Prototypes of both the variants were evaluated experimentally and the results are found consistent with numerical simulation. A material, mass and volume independent comparison revealed that both the variants are superior to most of the nested structures present in existing literature. Modularity, tunability and superior performance make C-4 a suitable candidate for current and future transportation systems.</p>

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Investigation on a modular nested tube energy absorber having adaptive tunability

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Vijay Kumar,
  • Jagmohan Datt Sharma,
  • Gaurav Pal Singh

摘要

Passenger safety during vehicle collision led to the requirements of improved crashworthiness. Most of the previous work is focused on standalone crashworthy structures having limited load adaptability and modularity. To mitigate these drawbacks, a novel metallic nested tube structure is proposed resulting increased energy absorption efficiency and modularity. The proposed energy absorber has fine as well as coarse step tunability to suit real world requirements. This structure comprises of three deformable structures i.e. Skin, Outer tube and Inner tube. Sensitivity analysis is performed to study the effect of skin thickness, outer tube thickness, inner tube thickness and number of inner tubes on energy absorption. Four types of nested structures namely C-1/C-2/C-3/C-4 are obtained by using 1/3/5/7 inner tubes. Numerically estimated MCF for C-1/C-2/C-3/C-4 are 7.85kN/10kN/13kN/18.16kN respectively. Due to highest MCF, C-4 is found to absorb 231%/181%/140% more energy than C-1/C-2/C-3. Multivariable optimization using L16 Taguchi design led to two variants. NTS4/4/4/4, containing maximum thickness of all deformable members and 7 inner tubes, is found to absorb highest energy. Whereas, NTS1/4/4/4 possessing combination of thinnest skin, thickest inner/outer tubes and 7 inner tubes reflected superior specific energy absorption. Prototypes of both the variants were evaluated experimentally and the results are found consistent with numerical simulation. A material, mass and volume independent comparison revealed that both the variants are superior to most of the nested structures present in existing literature. Modularity, tunability and superior performance make C-4 a suitable candidate for current and future transportation systems.