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<p>The energy absorbing box plays the role of buffering energy absorption in the process of frontal collisions of automobiles, but the current structure of the energy absorbing box is single, and the energy absorption effect is limited. In this study, a honeycomb structure was filled into a thin-walled square tube to design a new type of automotive energy absorbing box. Firstly, a frontal collision finite element model is established with a vehicle model as the research object, and the crashworthiness defects of the vehicle model under frontal collision conditions are pointed out. Next, two filling forms of new energy absorbing boxes were designed, and the crashworthiness was compared through impact simulation, followed by multi-objective optimization to further enhance their performance. Finally, the original thin-walled square tube energy absorbing box was replaced with the honeycomb-filled design. A simplified model was used to compare the crashworthiness of the vehicle before and after the replacement. The results showed that, after the replacement, the vehicle's acceleration decreased by 11.49%, the&#xa0;occupant compartment intrusion distance was reduced by 17.48%, and the energy absorption ratio of the energy absorbing box increased by 12.51%, enhancing&#xa0;crashworthiness and occupant safety.</p>

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Design of a New Energy Absorbing Box with Honeycomb Structure for Vehicles and Research on Vehicle Crashworthiness

  • 期刊论文

  • 发表日期：

    2025年5月21日

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  • Honglin Wang,
  • Zhanyu Wang,
  • Xuejing Du,
  • Ning Wang

摘要

The energy absorbing box plays the role of buffering energy absorption in the process of frontal collisions of automobiles, but the current structure of the energy absorbing box is single, and the energy absorption effect is limited. In this study, a honeycomb structure was filled into a thin-walled square tube to design a new type of automotive energy absorbing box. Firstly, a frontal collision finite element model is established with a vehicle model as the research object, and the crashworthiness defects of the vehicle model under frontal collision conditions are pointed out. Next, two filling forms of new energy absorbing boxes were designed, and the crashworthiness was compared through impact simulation, followed by multi-objective optimization to further enhance their performance. Finally, the original thin-walled square tube energy absorbing box was replaced with the honeycomb-filled design. A simplified model was used to compare the crashworthiness of the vehicle before and after the replacement. The results showed that, after the replacement, the vehicle's acceleration decreased by 11.49%, the occupant compartment intrusion distance was reduced by 17.48%, and the energy absorption ratio of the energy absorbing box increased by 12.51%, enhancing crashworthiness and occupant safety.