Perpustakaan Digital ITB

With the increasing emphasis on vehicle safety, there is a critical need to enhance the crashworthiness of automotive components. One such component is the crash box, which has a vital part in absorbing energy during collisions and protecting vehicle occupants. Improving the crash box design is essential for effectively absorbing impact energy during collisions, thereby reducing the forces transmitted to vehicle occupants and improving overall safety. This research addresses this need by optimizing the crashworthiness of double-walled sandwich crash box columns through the incorporation of an auxetic core with a re-entrant geometry and the application of the Design for Six Sigma (DFSS) methodology, specifically Taguchi’s method. Employing numerical simulations with LS-DYNA, the study explores the crashworthiness response of thin-walled columns with auxetic cores, focusing on their unique energy absorption properties. The DFSS utilizes an L18 Taguchi orthogonal array using the Signal-to-Noise (S/N) ratio with the criteria of larger-the-better. For the optimization, the factors used include adhesive bonding, core and wall material, re-entrant width and angle, and the thicknesses of the inner wall, outer wall, and core are selected as optimization parameters. The optimized crash box design features tied contact adhesive bonding, core, and wall materials of AL 6061-T6 and Ti-6Al-4V respectively, an auxetic width of 7 mm, an auxetic angle of 60 degrees, inner and outer wall thicknesses of 2 mm, and a core thickness of 1.5 mm. The main aspect analyzed is the Specific Energy Absorption (SEA) of the crash box, chosen for its effectiveness in quantifying energy absorption efficiency relative to the weight of the crash box. Therefore, the results shows that the optimized crash box with an auxetic structure and double walls shows significant improvement over the baseline design, with a yield gain of 35.84 and 11.53 for SEA and S/N ratio, respectively. These findings underscore the potential of advanced materials and structured design methodologies in enhancing vehicle safety and pave the way for future innovations in crashworthy structures.