Comparison of quasi-static compression characteristics of plain and vertically grooved square tubes for crashbox applications

Abstract

Crashworthiness research is crucial for advancing automotive safety by designing structures that effectively absorb and dissipate impact energy during collisions. This study uses numerical simulations and experimental tests to investigate the crashworthiness performance of Al6063 square tubes with and without a vertical square groove of 1 mm. The results demonstrate that adding a single vertical groove improved the total energy absorption (EA). The grooved tube absorbed 5136.21 J compared to 5082.54 J for the plain tube. Specific energy absorption (SEA) increased from 23.84 to 24.23 kJ/kg. The initial peak crushing force (IPCF) was reduced from 111.13 kN for the plain tube to 103.62 kN for the grooved tube, indicating enhanced crashworthiness. The mean crushing force (MCF) decreased from 67.02 kN to 60.88 kN, suggesting more controlled deformation. However, the crushing force efficiency (CFE) showed no improvement, declining slightly from 60.31% to 58.75%. The consistency between numerical and experimental results highlights the reliability of the methods used and confirms the potential of vertical grooves in improving specific crashworthiness parameters. These findings provide valuable insights for the design of energy-absorbing components in automotive applications.