Evaluation of energy absorption performance of cylindrical crash boxes with layered geometric modifications

¹ Department of Mechanical Engineering, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
² Department of Mechanical Engineering, Universitas Negeri Surabaya, Surabaya, Indonesia
³ Department of Materials and Metallurgical Engineering, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia
⁴ Department of Mechanical Engineering, Universitas Negeri Surabaya, Surabaya, Indonesia

^* Corresponding author: haruslg@me.its.ac.id

Published online: 22 December 2025

Abstract

The growing demand for transportation has resulted in an increase in vehicle production, thereby raising the risk of traffic accidents. Enhancing passive safety systems, such as crash boxes, is crucial to reducing the severity of collisions and safeguarding both passengers and critical vehicle components. This study examines the crashworthiness performance of four cylindrical crash box configurations: (a) base model, (b) cross-section reinforced, (c) single-layer, and (d) double-layer. A research and development approach was employed, involving the design, characterization, and simulation of each configuration using AA6061-T6 aluminum alloy. The evaluation was performed through numerical simulations under frontal impact conditions in accordance with NCAP standards. The key crashworthiness parameters assessed include energy absorption (EA), specific energy absorption (SEA), initial peak force (IPF), mean crushing force (MCF), and crush force efficiency (CFE). The results demonstrate that the double-layer configuration outperforms the other designs, achieving an EA of 5.102 kJ and a SEA of 15.22 kJ/kg, representing a 368.74% improvement in structural energy absorption compared to the base model. These findings underscore the effectiveness of layered geometric modifications in enhancing the crash performance of cylindrical crash boxes.