Comparative Study of Experimental Testing and Finite Element Simulation of Hexagonal Crash Boxes Made from AA 6061-T4

Ahmad Yunus Nasution (Department of Mechanical Engineering, Universitas Sumatera Utara, Medan 20155, Indonesia)
Dodi Peradile (Department of Mechanical Engineering, Universitas Sumatera Utara, Medan 20155, Indonesia)
Togu Martua Siregar (Department of Mechanical Engineering, Universitas Sumatera Utara, Medan 20155, Indonesia)
Riki Effendi (Department of Mechanical Engineering, Universitas Muhammadiyah Jakarta, DKI Jakarta 10510, Indonesia)
Gunawan Hidayat (Department of Mechanical Engineering, Universitas Muhammadiyah Jakarta, DKI Jakarta 10510, Indonesia)

SINTEK JURNAL: Jurnal Ilmiah Teknik Mesin
Vol. 19 No. 2 (2025): SINTEK JURNAL

This study evaluates the crashworthiness of hexagonal AA 6061-T4 crash boxes with perforations by integrating experimental compression tests and finite element (FEM) simulations. The research aims to analyze the influence of perforation patterns (one, two, and three holes) on energy absorption and deformation behavior. Simulation results using ABAQUS CAE 6.14 show strong agreement with experimental data, with discrepancies of less than 5% in peak force and energy absorption. The validated model confirms the effectiveness of perforated hexagonal designs in improving energy absorption while reducing peak reaction forces. These findings provide validated design insights for optimizing lightweight crash boxes and enhancing passive safety systems in automotive engineering.