Crashworthiness research is vital for designing structures that can absorb impact energy efficiently, ensuring safety in collisions. This study investigates the crashworthiness of Al6063 square tubes with and without horizontal grooves. Numerical simulations and experimental tests compared a plain tube with a grooved tube featuring four horizontal grooves. Results showed that adding grooves enhanced crashworthiness performance significantly. Total Energy Absorption (EA) and Specific Energy Absorption (SEA) improved by 4.85% and 4.92%, respectively, while the Initial Peak Crushing Force (IPCF) decreased by 16.81%, a favourable outcome for crash safety. Additionally, the grooved tube exhibited a 6.4% increase in Mean Crushing Force (MCF) and a 2.79% improvement in Crushing Force Efficiency (CFE). The strong agreement between numerical and experimental analyses highlights the reliability of numerical methods and the potential of grooved designs to optimize energy absorption and deformation characteristics. These findings contribute to the development of advanced energy-absorbing structures for automotive and industrial applications.
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