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Journal : Automotive Experiences

Collapse Behavior and Energy Absorption Characteristics of Design Multi-Cell Thin Wall Structure 3D-Printed Under Quasi Statistic Loads Wirawan, Willy Artha; Junipitoyo, Bambang; Putro, Setyo Hariyadi Suranto; Sabitah, A’yan; Suudy, Ahmad Hamim; Ridwan, Ridwan; Choiron, Moch. Agus
Automotive Experiences Vol 7 No 1 (2024)
Publisher : Automotive Laboratory of Universitas Muhammadiyah Magelang in collaboration with Association of Indonesian Vocational Educators (AIVE)

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.10892

Abstract

Crashworthiness is a passive device that has an important function as an absorbing component of the impact energy resulting from an accidental event. The main problem in the crashworthy design is the dimensional limitation on the front end of the vehicle with the driver so that most of the energy absorption is limited. Besides, the complexity of crashworthiness design is difficult to make conventionally. This research aims to find out the effectiveness of crashworthiness design in energy absorption and the resulting deformation patterns. Crashwortines are made in a multi-cell shape using PLA material and printed using a 3D printing raise machine. Crashworthiness is produced with four variation shapes of a Multi-cell circle (MCC), Multi-Cell square (MCS), Multicell pentagonal (MCP), and Multi-Cell pentagonal circles (MCPC) with a side thickness of 2 mm and a length of 150 mm. Experimental quasi-static testing is carried out in the frontal direction using a UTM machine at an operating speed of 2mm/s. The results of the study show that the design of the crash box of the pentagon circle has a significant increase in the energy absorption value of 62.49%, which can be recommended in future impact resistance tube designs. The characteristics of the deformation pattern and the failure resulting from the crashworthiness tend to form the pattern of the bending lamina failure. Failures can occur due to plastic fold, elastic bend, and pressure deformation mechanisms followed by new folding formations (lobes).
Effect of Tube Thickness Configuration of Two Segments Circular Crash Box on Its Crashworthiness Performance Hermawan, Muhammad Vendy; Choiron, Moch. Agus; Purnowidodo, Anindito; Winarto, Winarto
Automotive Experiences Vol 8 No 1 (2025)
Publisher : Automotive Laboratory of Universitas Muhammadiyah Magelang in collaboration with Association of Indonesian Vocational Educators (AIVE)

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31603/ae.13170

Abstract

This study aims to investigate the effect of tube configuration with different bottom fixation components on the energy absorption of a two-segment crash box. The circular tube thickness configuration has two thickness levels, half of the length of the tube has thicker walls (t2), and the other half has thinner walls (t1). The t1 values ​​are 1, 1.5, 2 and 2.5 mm while t2 is constant, 3 mm. Finite element analysis using ANSYS WORKBENCH was performed for the axial load model. The bottom fixation component uses Cutting Die Model (CDM) and Flat Model (FM). Sixteen crash box models were run to provide the effect of two tube thickness configurations and CDM-FM fixation components. The material of the circular tubes is Aluminum 6063 with a Bilinear Hardening Model assumption. Crashworthiness performance indicators were observed based on the values ​​of Energy Absorber (EA), Specific Energy Absorber (SEA), initial peak force (Fmax), and Crash Force Efficiency (CFE). The results show that the CDM model has the lowest Fmax value, due to the use of the die, which stimulates easier initial folding in the tube end area. The CDM model also has better SEA and CFE values. According to the results obtained from computer simulations, the CDM-t2t1 model with t1=1mm exhibited the highest Specific Energy Absorption (SEA) of 67.93 kJ. On the other hand, this same crash box model provided the smallest Fmax of 205.88 kN and the highest CFE value of 0.69. From these results, it can be concluded that this model provides the best crashworthiness performance.