Investigation and optimization of the energy absorption capacities of honeycomb filled hybrid structures

Energy absorbing structures are crucial structural elements utilized in various industries. In the automotive sector, energy absorbing structures ensure the safety of drivers and passengers within vehicles. Crash boxes are tasked with dampening the impact energy. Crash boxes are expected to be lightweight yet possess high strength. In this thesis, the crash performance of honeycomb-filled hybrid energy absorbing structures will be numerically determined. Due to the presence of different geometric and structural levels in the experimental design, the Taguchi experimental design has been employed. Following the 36 experimental designs, the TOPSIS method, a multi-criteria decision-making approach, will be utilized to achieve the optimal design. Material cards for the analysis models have been prepared through literature validation. The analysis model contained a significant number of contacts and elements, leading to a lengthy analysis solution process. To address this issue, a mass scaling study was conducted. A 10% weight increase reduced the analysis time by half. The appropriate analysis model was developed using the Python programming language and the TOPSIS code. Upon examining the obtained results, the model with the highest energy absorbing capacity has the highest TOPSIS score. The model with the highest score exhibits 22% greater energy dissipation capacity compared to an empty aluminum tube. Upon analyzing models with the highest TOPSIS scores, it was observed that the external tube material is carbon fiber-reinforced composite. Models with the lowest scores have an external and internal tube thickness of 1 mm, with a solid internal fill. Models with the lowest peak crushing values feature an aluminum external tube material, solid external fill, 80 mm external tube diameter, and 1 mm external tube thickness.