<p>Foam aluminum is regarded as an optimal energy-absorbing material. The incorporation of foam aluminum in automobile energy-absorbing structures not only improves energy absorption efficacy but also offers robust support for the lightweight design of new energy vehicles. Nonetheless, the present study has predominantly concentrated on optimizing energy-absorbing structures under singular cross-section or impact scenarios, overlooking the actual application demands of various circumstances. A innovative foam-filled elliptical conical tube (F-EN) construction has been proposed, integrating the benefits of elliptical cross-sections and conical forms to significantly improve energy absorption performance under complicated impact scenarios. Finite element models of five representative energy-absorbing structures, including the F-EN, were meticulously developed and validated by comparative analysis using experimental data to ensure model precision. A comprehensive performance evaluation framework was established, integrating three weighting strategies—Criteria importance through intercriteria correlation (CRITIC), Entropy weight method (EWM), and Same weight method (SWM)—to thoroughly assess the collision resistance of each structure under multi-angle conditions. Additionally, radial basis functions (RBF) and NSGA-II were utilized to optimize the geometric parameters of the F-EN structure. The optimized F-EN structure achieved a mass reduction of 33.67%, an increase in specific energy absorption of 33.8%, and a decrease in peak force of 21.79%. The research on energy-absorbing structures provides a feasible alternative for vehicle design under diverse operating situations, while also advancing the evaluation of performance assessment and optimization methods in these contexts, thereby promoting sustainable development.</p>

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Advanced optimization of crashworthiness in aluminum foam-filled elliptical conical tube structures

  • Xiurong Guo,
  • Aodi Bie,
  • Yanlin Zhang,
  • Danfeng Du

摘要

Foam aluminum is regarded as an optimal energy-absorbing material. The incorporation of foam aluminum in automobile energy-absorbing structures not only improves energy absorption efficacy but also offers robust support for the lightweight design of new energy vehicles. Nonetheless, the present study has predominantly concentrated on optimizing energy-absorbing structures under singular cross-section or impact scenarios, overlooking the actual application demands of various circumstances. A innovative foam-filled elliptical conical tube (F-EN) construction has been proposed, integrating the benefits of elliptical cross-sections and conical forms to significantly improve energy absorption performance under complicated impact scenarios. Finite element models of five representative energy-absorbing structures, including the F-EN, were meticulously developed and validated by comparative analysis using experimental data to ensure model precision. A comprehensive performance evaluation framework was established, integrating three weighting strategies—Criteria importance through intercriteria correlation (CRITIC), Entropy weight method (EWM), and Same weight method (SWM)—to thoroughly assess the collision resistance of each structure under multi-angle conditions. Additionally, radial basis functions (RBF) and NSGA-II were utilized to optimize the geometric parameters of the F-EN structure. The optimized F-EN structure achieved a mass reduction of 33.67%, an increase in specific energy absorption of 33.8%, and a decrease in peak force of 21.79%. The research on energy-absorbing structures provides a feasible alternative for vehicle design under diverse operating situations, while also advancing the evaluation of performance assessment and optimization methods in these contexts, thereby promoting sustainable development.