Abstract
Crash boxes in vehicles are one of the passive safety measures that aim to reduce injury to passengers and damage to the vehicle during a collision. Their function is to absorb the mechanical energy resulting from a collision by deforming plastically. Considering human safety, not only the energy must be damped, but also the forces acting on the passengers must be controlled. This force control can be adjusted to some extent using trigger mechanisms. There is a wide variety of research on hole type triggers, but they concentrated on traditional shapes; unique or hybrid shapes have not been sufficiently tested. This study examined the effects of various hole profiles with equal areas on dynamic mechanical performances of Al 6063-T6 rectangular crash boxes. Four types of trigger shapes were formed: upward keyhole, downward keyhole, U-shaped, and S-shaped. The dynamic performance evaluation was carried out experimentally by testing five types of geometries, the fifth one being the geometry without any trigger. In addition, dynamic Finite element analyses were conducted and validated using the experimental data, with the aim of employing the Finite element models in future geometry improvement studies. The experimental results were interpreted with some common evaluation parameters: peak force, crash force efficiency, mean crash force, and total energy absorption. The downward keyhole profile generally gave the best results, while the lowest peak force was observed in the U-shaped profile.
Funding source: THE SCIENTIFIC AND TECHNOLOGICAL RESEARCH COUNCIL OF TURKIYE
Award Identifier / Grant number: 118C125
Award Identifier / Grant number: 118C136
About the authors
Mehmet Kivanc Turan PhD born in 1991, received his BSc from Kocaeli University and his MSc from Bursa Technical University. As a scholarship holder of The Scientific and Technological Research Council of Türkiye (TUBİTAK), he is a co-worker of Grammer Koltuk Sistemleri A.Ş. His interest areas on welding, finite element methods, machine elements, vibration, topology optimization, and vehicle collision analysis.
Dr. Cihat Ensarioglu is currently a research assistant at the Department of Mechanical Engineering in Bursa Uludağ University, Bursa, Turkey. He received his BSc, MSc, and PhD degrees in Mechanical Engineering from the same university in 2003, 2007 and 2014, respectively. His research interests are production methods, materials, and mechanical characterisation.
Altug Bakirci PhD received his BSc in Mechanical Engineering Department from Kocaeli University in 2016. He helped establish the Electromobile student community in 2017 and led the production of electric vehicles for the TUBITAK – Teknofest International Efficiency Challenge Electric Vehicle race in 2018. He holds an M.Sc. degree in Mechanical Engineering from Bursa Uludag University with his master’s thesis about open-cell aluminum foam production in 2019. He is a PhD candidate at Bursa Uludag University, and a researcher in TUBITAK 2244 – Industrial PhD Fellowship Program, now. He has been working on additive manufacturing and printable electronics.
Prof. Dr. Fatih Karpat, born in 1977, Professor and head of mechanical engineering department at Bursa Uludag University. He received his BSc in 1998, MSc in 2001, and PhD in 2005 from Bursa Uludag University. He joined the academic community as research assistant in 1998 and he continued his success by gaining the title of associate professor in 2015 and professor in 2020. He has been to Texas Tech University and University of Central Oklahoma between 2006 and 2015 for postdoctoral and guest researcher. His professions based on machine elements, energy, biomedical engineering, sustainability, MEMS, and technological innovations. He has more than 20 science citation indexed publications, 5 book chapters, more than 70 academic conference publications. Beside the academic side, he also managed more than 20 industrial projects.
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Research ethics: Not applicable.
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Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
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Competing interests: The authors state no conflict of interest.
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Research funding: The Scientific and Technological Research Council of Turkiye Award numbers: 118C125, 118C136.
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Data availability: Not applicable.
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