Analysis and Development of Energy absorbing crash box.

Mechanical Engineering

Crash box is a separate component in vehicle which is mounted in between main frame of the car and front bumper. At the time of the accident it deforms axially and absorbs accidental energy. Crash box structure provides comfort to the passenger at the time of impact. It works as safe guard for the costly components behind the bumper like engine hood, cooling system In this report plane crash box geometry is studied for the energy absorption. Study is based on analytical, experimental and numerical work. Various parameters like width, thickness, taper those affect on the crash box performance are studied by using Design of experiments in Minitab 17. Crash box crushing behavior is analyzed by using quasi static method. Experimental test is performed on UTM machine. Quasi-static simulation is performed using ANSYS Explicit Dynamic workbench with its Auto-Dyna solver. Good agreement obtained in the results of analytical, experimental and numerical method. By varying the parameters and application of beads different designs are proposed and simulated for the maximum energy absorption. Application of various positioned beads shows good influence on the energy absorption.

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