| Numerical Investigation of Energy Absorption in Graded Honeycomb-Filled Composite Crash Box Structures |
| Sura Thaer Bader, Mohsin N. Hamzah, Qasim Abbas Atiyah |
| Mechanical Engineering Department, University of Technology, Baghdad, 10066, Iraq |
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Received: December 18, 2024; Revised: July 1, 2025 Accepted: July 1, 2025. Published online: August 28, 2025. |
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| ABSTRACT |
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Structural crashworthiness is critical in vehicle design, as it directly impacts occupant safety during collisions. The crash box, located between the bumper and side rails, absorbs impact energy, reduces vehicle damage, and protects passengers. Enhancing its energy absorption capacity is essential for improving vehicle safety. Honeycomb fillers are widely used for their high stiffness, energy absorption, and ability to ensure controlled crushing while minimizing peak force. This study evaluates three crash box designs under impact tests using a 600 kg impactor. Sample S1 was an empty crash box, S2 was filled with graded-cell thickness honeycomb, and S3 was filled with graded-cell size honeycomb. Numerical simulations were conducted using the ABAQUS software. Results showed that S3 outperformed S1 and S2, demonstrating superior energy absorption (19.56 kJ vs. 2.35 kJ and 7.97 kJ, respectively), specific energy absorption (5.93 kJ/kg vs. 1.16 kJ/kg and 2.67 kJ/kg), and crush force efficiency (43.90 vs. 25.30 and 31.09). The S3 design's graded-cell size structure ensured uniform deformation, consistent folding patterns, and maximized compression, enhancing crashworthiness. These findings highlight the importance of tailored structural designs in optimizing energy absorption and improving vehicle safety. |
| Key Words:
Crash box · Crashworthiness design · Graded honeycomb · Energy absorption · Finite element analysis |
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Corresponding Author.
Mohsin N. Hamzah , Email. 
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