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The research is to make an optimized crush box to resist the crash with nominal damage on low-speed impact in a vehicle. The main objective is to find out the best crush box to pull off maximum energy absorption. The crush box was designed with different amalgamation-like shapes, strength, ribs and crush initiators. The different types of crush boxes were designed with the help of design software, according to the design of experiments (Taguchi L9 array). The numerical models were developed to forecast the result, and obtained results were in good consistent with the experimental result. Finally, the optimized design obtained from the study was tube-shaped high-strength steel material with two ribs and without a crush initiator, which absorbs the maximum energy. Also, the carbon steel shows ferromagnetic properties, with help of this after impact using magnetic field to regain its shape partial which lead to easy repair.

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Optimization of Carbon Steel Vehicle Crush Box by Varying Design Parameters for Low-Speed Impact Application

  • 会议论文

  • 发表日期：

    2026年

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  • Thiyagu Chenniappan,
  • N. Sathiesh Kumar,
  • P. Ragupathi,
  • V. Santhosh,
  • M. Prem Kumar

摘要

The research is to make an optimized crush box to resist the crash with nominal damage on low-speed impact in a vehicle. The main objective is to find out the best crush box to pull off maximum energy absorption. The crush box was designed with different amalgamation-like shapes, strength, ribs and crush initiators. The different types of crush boxes were designed with the help of design software, according to the design of experiments (Taguchi L9 array). The numerical models were developed to forecast the result, and obtained results were in good consistent with the experimental result. Finally, the optimized design obtained from the study was tube-shaped high-strength steel material with two ribs and without a crush initiator, which absorbs the maximum energy. Also, the carbon steel shows ferromagnetic properties, with help of this after impact using magnetic field to regain its shape partial which lead to easy repair.