Enhanced Crash Box Energy Absorption: Impact of Single Screw Integration - A Finite Element Analysis Study

This study proposes a novel energy absorber design by incorporating a screw into the groove of crash boxes and evaluates its performance using finite element analysis (FEA). The methodology integrates CAD modelling, material characterization, and detailed analysis of simulation data to assess the influence of single screw integration on crash box performance. LS-Dyna simulation is employed to investigate the behaviour of Aluminium Alloy 5052 (Al5052) crash boxes with screws in the groove. Results from FEA reveal key performance indicators such as displacement, stress, strain, internal energy, and acceleration across various crash box thicknesses. Analysis of the data demonstrates that as the thickness of the crash box increases, there is a trend of decreasing displacement, stress levels, and acceleration. The presence of the screw leads to reductions in stress levels and acceleration across different thicknesses of crash boxes, indicating superior performance. These findings suggest that the proposed design holds promise for reinforcing vehicle safety systems, particularly in low-speed crash scenarios. Overall, this study contributes to advancements in automotive safety and crashworthiness methodologies by optimizing energy absorption mechanisms, acceleration control strategies, and strain management techniques in crash box design. Future research directions include exploring advanced materials and structural designs to further enhance crash box performance and adaptability to different collision scenarios.