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In this paper, the impact resistance of newly structured corrugated crash boxes with an increased number of corrugations was studied during axial crushing. To achieve this, various designs of corrugated crash boxes made from Mild Steel St37 were selected, maintaining the same dimensions of corrugations while increasing the number of corrugations. The axial crushing behavior of corrugated crash boxes under impact forces was investigated using finite element simulations and models created using LS-DYNA in ANSYS. Important parameters like crush force efficiency, specific energy absorption, and dynamic crushing force amplitude were computed theoretically. These measurements were then contrasted with models with more corrugations. The findings showed that crash boxes with more corrugations have the advantage of having a lower initial collapse force as well as higher values for metrics like specific energy absorption and crush force efficiency. Moreover, the amplitude of crushing force fluctuations and parameters such as crush force efficiency (CFE), energy absorbed, and specific energy absorbed (SEA) were higher compared to boxes with fewer corrugations. The findings from the study on corrugated crash boxes highlight their significant advantages in enhancing safety during collisions.

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Comparative Study on the Corrugation Configuration of the Crash Box to Enhance Energy Absorption Capacity During Axial Crushing

  • 会议论文

  • 发表日期：

    2026年

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  • Minhhieu Pham,
  • Truong Huy Phong,
  • Nguyen Trung Kien,
  • Hung Chu Duc,
  • Do Van Tuan,
  • Dinh Van Tra,
  • Pham Ba Nhat,
  • Luu Ba Quynh

摘要

In this paper, the impact resistance of newly structured corrugated crash boxes with an increased number of corrugations was studied during axial crushing. To achieve this, various designs of corrugated crash boxes made from Mild Steel St37 were selected, maintaining the same dimensions of corrugations while increasing the number of corrugations. The axial crushing behavior of corrugated crash boxes under impact forces was investigated using finite element simulations and models created using LS-DYNA in ANSYS. Important parameters like crush force efficiency, specific energy absorption, and dynamic crushing force amplitude were computed theoretically. These measurements were then contrasted with models with more corrugations. The findings showed that crash boxes with more corrugations have the advantage of having a lower initial collapse force as well as higher values for metrics like specific energy absorption and crush force efficiency. Moreover, the amplitude of crushing force fluctuations and parameters such as crush force efficiency (CFE), energy absorbed, and specific energy absorbed (SEA) were higher compared to boxes with fewer corrugations. The findings from the study on corrugated crash boxes highlight their significant advantages in enhancing safety during collisions.