Restricted accessResearch articleFirst published online 2025
Numerical investigation on the quasi-static compression characteristics of bio-inspired vertically grooved square tubular structure for the application in crashbox
This study enhances the crashworthiness of Al6063 square tubes by investigating vertical grooves on energy absorption and deformation control. Numerical simulations evaluated tubes with 1 mm deep and wide vertical grooves in configurations of 2, 4, 6 and 8 grooves, compared to a plain tube. Finite Element Analysis (FEA) assessed key crashworthiness parameters: Energy Absorption (EA), Specific Energy Absorption (SEA), Initial Peak Crushing Force (IPCF), Mean Crushing Force (MCF) and Crushing Force Efficiency (CFE). The two-groove configuration achieved an 11.11% increase in EA, a 12.79% improvement in SEA, a 7.89% reduction in IPCF and a 2.09% enhancement in CFE. Configurations with more grooves exhibited reduced performance, with minimal impact on MCF. The two-groove design optimally balanced crashworthiness parameters, confirming its effectiveness in improving energy absorption and deformation control. This research highlights the role of vertical groove configurations in enhancing crashworthiness and provides valuable insights for designing advanced energy-absorbing structures in automotive and structural engineering.
AydınMM. The modeling of effective parameters on public bus passengers’ boarding time prediction. J Eng Res2021; 10(1B): 1–16.
2.
Farokhi NejadAAlipourRShokri RadM, et al. Using finite element approach for crashworthiness assessment of a polymeric auxetic structure subjected to the axial loading. Polymers2020; 12: 1312.
3.
OmalleyS. Crashworthiness testing of electric and hybrid vehicles. In: 24th International technical conference on the enhanced safety of vehicles (ESV) national highway traffic safety administration, 2015.
4.
BorovinšekMVesenjakMUlbinM, et al. Simulation of crash tests for high containment levels of road safety barriers. Eng Fail Anal2007; 14: 1711–1718.
5.
XuFTianXLiG. Experimental study on crashworthiness of functionally graded thickness thin-walled tubular structures. Exp Mech2015; 55: 1339–1352.
6.
XiaoYWenXLuS, et al. Analysis of factors affecting crashworthiness of CFRP thin-walled square tubes filled with gradient aluminum foam. J Mater Eng Perform2024; 33: 7334–7344.
7.
FadeelAAbdulhadiHSrinivasanR, et al. A computational approach in understanding the low-velocity impact behavior and damage of 3D-printed polymer lattice structures. J Mater Eng Perform2021; 30: 6511–6521.
8.
LockhartPACroninDSWatsonB. Frontal impact response for pole crash scenarios. Traffic Inj Prev2013; 14: 509–519.
9.
MohsenizadehSAhmadZAliasA. Numerical prediction on the crashworthiness of circular and square thin-walled tubes with polymeric auxetic foam core. J Mater Eng Perform2020; 29: 3092–3106.
10.
ZhangZGuoCWangL, et al. Crashworthiness of bio-inspired hierarchical hybrid multi-cell tubes under axial crushing. Eng Fail Anal2024; 166: 108886.
11.
BidadiJArabhaMSaeidi GoogarchinH. Adhesive bonding in automotive hybrid multi-cell square tubes: experimental and numerical investigation on quasi-static axial crashworthiness performance. Int J Adhes Adhes2024; 135: 103832.
12.
LuoGLiuJLiL, et al. Crashworthiness analysis and multi-objective optimization design for foam-filled spiral tube. Int J Mech Sci2024; 282: 109588.
13.
XiaoYWuQWLiuY, et al. Optimization design of crashworthiness of polyurethane foam filled Origami thin wall square tube based on an surrogate model. Structures2024; 65: 106713.
14.
ZhangJWangLPengD, et al. Crashworthiness optimization of a sandwich tube filled with CFRP sinusoidal corrugated board. Aerosp Sci Technol2023; 132: 108065.
15.
JaikumarMKoenigPVigneshSK, et al. Impact of vehicle collision using modified crash box in the crumple zone - a perspective assessment. Int J Veh Struct Syst2022; 14: 524-529.
MaWXieSLiZ. Mechanical performance of bio-inspired corrugated tubes with varying vertex configurations. Int J Mech Sci2020; 172: 105399.
18.
FuJLiuQLiufuK, et al. Design of bionic-bamboo thin-walled structures for energy absorption. Thin-Walled Struct2019; 135: 400–413.
19.
HuangHXuS. Crashworthiness analysis and bionic design of multi-cell tubes under axial and oblique impact loads. Thin-Walled Struct2019; 144: 106333.
20.
ZhangHHuDPengH, et al. In-plane crashworthiness study of bio-inspired metallic lattice structure based on deep-sea glass sponge. Thin-Walled Struct2024; 205: 112505.
21.
LiRZhaoZBaoH, et al. Bio-inspired honeycomb structures to improve the crashworthiness of a battery-pack system. Eng Fail Anal2024; 158: 108041.
22.
LeDNovakNArjunanA, et al. Crashworthiness of bio-inspired multi-stage nested multi-cell structures with foam core. Thin-Walled Struct2023; 182: 110245.
23.
DoanTNguyenTLu̕o̕ngV, et al. Study of the in-plane crashworthiness performance of 6-legged starfish-inspired structures. Proc IMechE, Part L: J Materials Design and Applications2024; 238: 634–650.
24.
HaNSPhamTMChenW, et al. Crashworthiness analysis of bio-inspired fractal tree-like multi-cell circular tubes under axial crushing. Thin-Walled Struct2021; 169: 108315.
25.
XingJZhaoJNiuQ, et al. Crashworthiness design and optimization of bamboo-inspired tube with gradient multi-cells. Thin-Walled Struct2023; 191: 111034.
26.
MengZCan-gangWJian-qiaoL, et al. The energy absorption of bamboo under dynamic axial loading. Thin-Walled Struct2015; 95: 255–261.
27.
SinghSKPandeyRUpadhyayA. A numerical study on combined effects of groove shape and numbers on crashworthiness characteristics of thin-walled tube. Mater Today2021; 44: 4381–4386.
28.
DaneshiGHHosseinipourSJ. Grooves effect on crashworthiness characteristics of thin-walled tubes under axial compression. Mater Eng 20022002; 23: 611–617.
29.
LiQFLiuYJWangHD, et al. Finite element analysis and shape optimization of automotive crash-box subjected to low velocity impact. In: 2009 International conference on measuring technology and mechatronics automation, 2009. IEEE.
30.
SassoMSarasiniFManciniE, et al. Experimental characterization and numerical modelling of the impact behavior of PVC foams. Exp Mech2023; 63: 823–837.
31.
ShuvhoMBAChowdhuryMAHossainN, et al. Tribological study of Al-6063-based metal matrix embedded with SiC–Al2O3–TiO2 particles. SN Appl Sci2020; 2: 287.
32.
IdreesUAhmadSShahIA, et al. Finite element analysis of car frame frontal crash using lightweight materials. J Eng Res2023; 11: 100007.
33.
GongCBaiZLvJ, et al. Crashworthiness analysis of bionic thin-walled tubes inspired by the evolution laws of plant stems. Thin-Walled Struct2020; 157: 107081.
34.
HaluzaRTRuggeriCRPereiraJM, et al. Novel crash sled with a translating support mass. Exp Mech2022; 62: 715–728.
35.
QiuNGaoYFangJ, et al. Crashworthiness analysis and design of multi-cell hexagonal columns under multiple loading cases. Finite Elem Anal Des2015; 104: 89–101.
36.
MuraliAArumugamPShanmugamV, et al. Numerical investigation on the quasi-static compression characteristics of bio-inspired horizontally grooved square tubular structure for the application in crash boxes. Proc IMechE, Part L: J Materials Design and Applications 2025. Epub ahead of print March2, 2025. DOI: 10.1177/14644207251322258
37.
ZouMXuSWeiC, et al. A bionic method for the crashworthiness design of thin-walled structures inspired by bamboo. Thin-Walled Struct2016; 101: 222–230.
38.
MaWLiZXieS. Crashworthiness analysis of thin-walled bio-inspired multi-cell corrugated tubes under quasi-static axial loading. Eng Struct2020; 204: 110069.
39.
Christy AlbertPRadzi Ab GhaniAZaid OthmanM, et al. Axial crushing behavior of aluminum square tube with origami pattern. Mod Appl Sci2016; 10: 90.
40.
SongJFXuSCWangHX, et al. Bionic design and multi-objective optimization for variable wall thickness tube inspired bamboo structures. Thin-Walled Struct2018; 125: 76–88.
41.
Özbek BozkurtÖYErkliğA. An experimental study on intraply fiber hybridization of filament wound composite pipes subjected to quasi-static compression loading. Polym Test2019; 79: 106082.
