Crush Can Behaviour as an Energy Absorber in a Frontal Impact

The work presented is devoted to the investigation of a state-of-the-art technological solution for the design of a crush-can characterized by optimal energy absorbing properties. The work is focused on the theoretical background of the square tubes, circular tubes and inverbucktube performance under impact with the purpose of design of a novel optimized structure. The main system under consideration is based on the patent US 2008/0185851 A1 and includes a base flange with elongated crush boxes and back straps for stabilization of the crush boxes with the purpose of improvement of the energy-absorbing functionality. The modelling of this system is carried out applying both a theoretical approach and finite element analysis concentrating on the energy absorbing abilities of the crumple zones. The optimization process is validated under dynamic and quasi-static loading conditions whilst considering various modes of deformation and stress distribution along the tubular components. Energy absorbing behaviour of the crush-cans is studied concentrating on their geometrical properties and their diamond or concertina modes of deformation. Moreover, structures made of different materials, steel, aluminium and polymer composites are considered for the material effect analysis and optimization through their combination. Optimization of the crush-can behaviour is done within the limits of the frontal impact scenario with the purpose of improvement of the structural performance in the Euro NCAP tests.