Session: ASME Undergraduate Student Design Expo

Paper Number: 167213

Crashworthiness and Energy Absorption Analysis of Lattice Structures and Hybrid Configurations Using Finite Element Simulations 

Lattice structures have gained widespread attention in engineering due to their exceptional strength-to-weight ratio, energy absorption capacity, and tunable mechanical properties. These features make them highly suitable for crashworthiness applications in automotive, aerospace, and defense industries, where impact mitigation and structural integrity are critical. The ability of lattice structures to undergo controlled deformation and dissipate energy efficiently is key to enhancing safety and performance. However, different lattice configurations exhibit varying crash responses depending on their geometry, material properties, and boundary conditions. Additionally, combining different lattice types into hybrid structures may provide enhanced energy absorption characteristics by leveraging the strengths of each configuration. Therefore, this study investigates the crashworthiness of various lattice structures and their hybrid combinations using finite element analysis (FEA) to evaluate their energy absorption performance under high-impact conditions.

We model and simulate different lattice configurations, including Kelvin cell, octet truss, honeycomb, and body-centered cubic (BCC) structures to analyze the crash behavior. Additionally, we examine hybrid lattice structures combining two or more configurations to explore potential improvements in energy dissipation and deformation behavior. These structures are subjected to dynamic impact simulations using explicit finite element solvers, considering different impact velocities, loading conditions, and material properties. Key crashworthiness parameters such as specific energy absorption (SEA), peak impact force, deformation modes, and failure mechanisms are analyzed. The study also investigates how gradient density distributions and strut thickness variations influence the overall crash performance of these structures.

Preliminary results indicate that lattice structures with gradual density variations provide superior energy absorption by enabling progressive and controlled collapse, effectively reducing peak impact forces. Kelvin and octet truss configurations exhibit stable deformation patterns and efficient stress distribution among the individual lattice structures, leading to higher SEA values. In contrast, honeycomb and BCC structures display localized failure zones, which could concentrate impact forces and reduce overall crashworthiness. Hybrid lattice structures, which integrate different configurations, demonstrate potential improvements in energy dissipation by combining the strengths of each lattice type. For instance, structures incorporating a stiffer outer lattice with a more flexible core show better shock absorption and controlled collapse behavior, enhancing impact mitigation.

This research comprehensively analyzes crashworthy lattice structures and their hybrid configurations, combining high-fidelity finite element modeling with energy absorption evaluation. The findings contribute to developing optimized lattice designs for crash-resistant applications, including vehicle impact protection, aerospace safety structures, and protective equipment. Future work will include experimental validation using additively manufactured specimens, ensuring that numerical predictions align with real-world impact testing. By integrating computational modeling with experimental analysis, this study helps advance the design of lightweight, high-performance, impact-resistant structures, offering valuable insights for industries that rely on efficient energy absorption technologies.

Presenting Author: Kenteya Stubbs Kettering University

Presenting Author Biography: Kenteya Stubbs is an undergraduate student in the Mechanical Engineering Department at Kettering University.

Authors:

Seyed Jamaleddin Mostafavi Yazdi Kettering University
Kenteya Stubbs Kettering University