Session: 04-11-03: Advanced Materials Processing and Property Characterization

Paper Number: 146015

146015 - Enhancing Energy Absorption Capacity of Thin-Walled Box Structures Through the Integration of Auxetic Materials 

In frontal impacts, the usage of thin-walled box structures in the front-end of vehicles is crucial for effectively absorbing collision energy. However, achieving maximum energy absorption while considering constraints such as available space, weight, cost, and maintaining occupant safety is a challenging task. Previous studies have indicated that the structural shape, utilization of high strength materials, and incorporating foam-filled structures can significantly enhance energy absorption capacity. This paper introduces a novel approach to optimize the energy absorption capacity with a combination of conventional and auxetic materials. Auxetic materials possess a unique characteristic of exhibiting a negative Poisson's ratio, which means they contract when compressed and expand when subjected to tension. These distinctive properties enable auxetic structures to achieve higher stiffness and improved impact resistance while remaining lightweight.

In this paper, a Finite Element Analysis (FEA) methodology has been formulated with a simple crush box, and with multiple materials combinations of conventional materials such as high strength steels, Aluminum and auxetic materials, to improve the energy absorption capacity. The significant factors affecting the energy absorption which are critical to occupant safety have been compared between the simulations. It is demonstrated that the optimal blend of conventional materials such as Aluminum and Ultra High Strength Steels, when integrated with auxetic structures, exhibits a higher potential for maximizing the specific energy absorption capacity of these structures. The findings reveal that the optimized combination of the above-mentioned materials can increase the specific energy absorption (SEA) capacity by up to 256%. Additionally, the practical application of these findings is demonstrated through full vehicle level crash analyses aimed at achieving lightweighting. The research findings were implemented on the Ford Taurus FE model, validated experimentally and available online, showing achieved benefits of 7.83kg weight reduction with retaining same crash performance as baseline.

In frontal impacts, the usage of thin-walled box structures in the front-end of vehicles is crucial for effectively absorbing collision energy. However, achieving maximum energy absorption while considering constraints such as available space, weight, cost, and maintaining occupant safety is a challenging task. Previous studies have indicated that the structural shape, utilization of high strength materials, and incorporating foam-filled structures can significantly enhance energy absorption capacity. This paper presents a novel approach to optimize the energy absorption capacity with a combination of conventional and auxetic materials. Auxetic materials possess a unique characteristic of exhibiting a negative Poisson's ratio, which means they contract when compressed and expand when subjected to tension. These distinctive properties enable auxetic structures to achieve higher stiffness and improved impact resistance while remaining lightweight.

Presenting Author: Peddi Sai Rama Narayana Mahindra Research Valley

Presenting Author Biography: Senior Principal Engineer - CAE, Mahindra Research Valley, Chengalpattu, Tamilnadu, India.

Authors:

Peddi Sai Rama Narayana Mahindra Research Valley
Raghu Prakash Indian Institute of Technology Madras
Srinivas Gunti Indian Institute of Technology Madras
Raghu Kanugula Mahindra Research Valley