Design and Development of Circular Crash Boxes: Evaluating Single and Dual Screw-Groove Configurations for Enhanced Crashworthiness

This study investigates the design and development of circular crash boxes aimed at enhancing crashworthiness through the analysis of screw-groove configurations. Two specific designs were evaluated: one featuring a single screw in two grooves and another incorporating two screws in four grooves. Finite Element Method (FEM) simulations were conducted using LS-DYNA, wherein a 700 kg impactor struck the crash boxes at varying velocities. The materials tested included Al5052 aluminium alloy and mild steel. In this study, we assessed and compared key crashworthiness performance metrics to evaluate the effectiveness of energy-absorbing structures. Results indicated that higher impact velocities led to increased energy absorption and peak forces but resulted in decreased crush force efficiency. Notably, the configuration with two screws in four grooves exhibited superior energy absorption and more favourable load distribution compared to the single screw design. These findings underscore the importance of optimizing screw-groove configurations to improve crashworthiness. This research offers valuable insights for designing more effective crash boxes to enhance occupant protection during collisions. Keywords: Crashworthiness, Screw-Groove Configuration, Impact Testing, Axial Impact