Optimization of Energy Absorption and Deformation Characteristics of Aluminium Crash Box with the Effect of Groove along with a Screw

The Crash box is the mechanical component that absorbs the impact energy by axial deformation. When an accident occurs, energy absorption and deformation play a vital role in the Automobile safety aspects, and also grooves and triggers are the ones included in the crash box for axial folding and uniform deformation. Here in this research paper, the energy absorption of kinetic energy and deformation parameter is going to be compared with the crash box with the groove at different thicknesses, also the groove is added through the vertical axis along with axial crush occurs. The modeling is done in Hyper mesh 2021 and the simulation and result validation in LS Dyna. The primary goal of this research project is to increase the crash box’s efficiency and enhance the crashworthiness and the passive safety of the passenger vehicle. It is also observed that the groove plays a vital role in reducing the acceleration transmitted to the surrounding area. The box sleeve with screw run through the groove first which almost absorbs 20% of impact energy and the remaining will be absorbed during full axial folding of the crash box. The rupture will happen along with the failure of the grooves when the screw moves, thus improving the energy absorption in the crash box, this kind of screw-type crash box was also easy to replace after the collision. Further, this simulation result will be compared with the crash box without a groove. The improvisation of crashworthiness in the crumple zone of the passenger car is the primary goal of this research. The research findings provide a valuable reference for the design of crash box constructions.