Abstract
Within this paper methods in reducing weight and optimizing the front-end structure, by specifically targeting both new materials and redesigning the cashbox, to improve crashworthiness were investigated. This was accomplished through redesigning the cross-sectional shape of the crash box, trigger location and type of trigger used, and the use of different materials. The optimal crash box design was found to be a hexagonal prism that incorporated a central trigger which reduced the thickness from 2mm to 1mm. Moreover, the ideal material was identified to be SGF/PA6/GnPls. When this optimized crash box was incorporated to the front-end structure and the ideal material applied to the bumper beam, the fully optimized front-end structure reduced the weight by 75%, reduced peak force by 28% and increased specific energy absorption by 94% and 55% for a frontal and side collision respectively.
