Design analysis of a circular aluminum crashbox for a frontal accident protection

Mohd Isa, Fatin Aqillah (2017) Design analysis of a circular aluminum crashbox for a frontal accident protection. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Crash box has function to absorb energy resulted of the crash during frontal collision. It typically designed to be structural components that would significantly contribute to vehicle crashworthiness or occupant protection during front or rear collisions. Crash protection features is an important factor to have high injury protection to the passenger if it was built from the best material which can absorb more energy during accident happen. However, crash box has different type of shape such as rectangular and circular, different cross sectional area and material that can be used like by using aluminium or steel. Then, all of that criteria had different momentum of impact and different amount of energy absorption depending on the dimension, length, width, thickness of material and loading condition used. The aim of this project is to design and analysis of a Circular Aluminium Crash box for Frontal Accident Protection system of car. An analysis of a car ordinary crash situation is performed by use of ANSYS software as a solver and with following analysis related to the accident protection crash box. The main focus of this study is to design and do analysis on the crash box by using ANSYS software. In order to calculate maximum energy absorption to the crash box, optimization to the crash box was done manually. Four types of crash box with different diameter of 50mm, 60mm,70mm and 80mm was design and undergoes the same simulation analysis by using the same software to get the kinetic energy then the energy absorption can be calculated and compared to get the maximum energy absorption. From the result, energy absorption increase by increasing the diameter of the crash box which the value of 50mm, 60mm, 70mm and 80mm are 9965J, 12123J, 13059J and 14555J. Thus, by increasing the diameter of crash box, the more energy can be absorb so, passenger can be prevent from fatal injury.

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