Effect of number of triggers and shape of crash box on energy absorption during experimental collision

The capacity of passenger car crash boxes to absorb energy during crashes has been the subject of extensive research, which started with the creation of multiple crash box models, changes in crash box filling, and the inclusion of crash box triggers. On the other hand, no research has been done on the combination of axle trigger holes, nine-cell columns, and crash box models. The results of the experiment on the energy-absorbing capacity of AA6061-T4 crash box specimens under compressive loads are presented in this paper. The compression tests were conducted on a Universal Testing Machine with a maximum force capability of 1000 kN and a speed capability of 5 mm/s. Three models are used in crash box modeling. A cross-section of the model with a round hole-shaped trigger variation is included in these three versions. It is established that the hexagonal Frusta type with two holes absorbs the highest energy at 33.30 kJ, and has a displacement of 4.12 mm and a maximum force of 348.5 kN. The energy absorption capacity of the crash box was found to be increased by combining frusta versions of the hexagon model with two holes and nine-cell column filling.