Low-velocity crashworthiness and optimization of a crash box filled with modularized graded honeycomb

Purpose Graded honeycombs are materials that exhibit better energy absorption performance compared to uniform honeycombs without adding additional weight. This paper introduces a novel modularized graded honeycomb into a commercial crash box to improve its crashworthiness. Design/methodology/approach A modularized graded honeycomb is inserted into a commercial crash box to develop a novel crash box. Finite element analyses are conducted to investigate the crashworthiness. Pareto cumulative influence analysis is conducted to rank the effects of design parameters on crashworthiness. A surrogate model-based multi-objective optimization is carried out to improve energy absorption while limiting the impact peak force. An optimal Pareto solution set is obtained. Findings Modularized honeycomb-filled crash box outperforms that of its corresponding uniform honeycomb-filled crash box and empty crash box in resisting impact. Pareto cumulative influence analysis reveals that for most crashworthiness indicators, cell-wall thicknesses of crash box tube contribute the most, followed by average relative density and graded coefficient of modularized honeycomb (MH). Graded coefficient contributes nearly 10% on mean force and maximum displacement, but it has insignificant influence on peak force and weight. Optimization results show that the optimal designs can not only absorb more energy but also limit the peak force compared with those of uniform honeycomb-filled crash box. Originality/value This paper fills a MH into a commercial crash box to propose a novel crash box and demonstrates the positive impact of modularized design on crashworthiness compared with that of uniform honeycomb-filled crash box. Moreover, modularizing honeycomb does not change the weight of the filler, and thus, the novel crash box would benefit development of crash box with lightweight and excellent energy absorption capacity.