On the Performance of Thin-Walled Crash Boxes Joined by Forming

Diogo  F. M. Silva; Carlos M.A.  Silva; Ivo  M. F. Bragança; Chris V. Nielsen; Luis M. Alves; Paulo A.F. Martins

doi:10.3390/ma11071118

On the Performance of Thin-Walled Crash Boxes Joined by Forming

Diogo F. M. Silva
, Carlos M.A. Silva
, Ivo M. F. Bragança
, Chris V. Nielsen
, Luis M. Alves
, Paulo A.F. Martins^*

^*Corresponding author for this work

University of Lisbon
Instituto Superior de Engenharia de Lisboa

Research output: Contribution to journal › Journal article › Research › peer-review

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Abstract

A new joining by forming process that combines lancing and shearing with sheet-bulk compression is utilized to assemble thin-walled crash boxes utilized as energy absorbers. Process design and fabrication of the new crash boxes are analyzed by finite elements and experimentation. Axial crush tests were performed to compare the overall crashworthiness performance of the new crash boxes against that of conventional crash boxes assembled by resistance spot-welding. Results show that the joining process is a good alternative to resistance spot-welding because the new crash boxes can absorb the same crushing energy, and because the new process helps to overcome typical manufacturing problems of welding.

Original language	English
Article number	1118
Journal	Materials
Volume	11
Number of pages	15
ISSN	1996-1944
DOIs	https://doi.org/10.3390/ma11071118
Publication status	Published - 2018

Bibliographical note

© 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).

Keywords

Crash boxes
Joining by forming
Resistance spot-welding
crashworthiness

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10.3390/ma11071118

Materials 11 01118Final published version, 4.19 MB

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title = "On the Performance of Thin-Walled Crash Boxes Joined by Forming",

abstract = "A new joining by forming process that combines lancing and shearing with sheet-bulk compression is utilized to assemble thin-walled crash boxes utilized as energy absorbers. Process design and fabrication of the new crash boxes are analyzed by finite elements and experimentation. Axial crush tests were performed to compare the overall crashworthiness performance of the new crash boxes against that of conventional crash boxes assembled by resistance spot-welding. Results show that the joining process is a good alternative to resistance spot-welding because the new crash boxes can absorb the same crushing energy, and because the new process helps to overcome typical manufacturing problems of welding.",

keywords = "Crash boxes, Joining by forming, Resistance spot-welding, crashworthiness",

author = "\{F. M. Silva\}, Diogo and Silva, \{Carlos M.A.\} and \{M. F. Bragan{\c c}a\}, Ivo and Nielsen, \{Chris V.\} and Alves, \{Luis M.\} and Martins, \{Paulo A.F.\}",

note = "{\textcopyright} 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).",

year = "2018",

doi = "10.3390/ma11071118",

language = "English",

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journal = "Materials",

issn = "1996-1944",

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AU - M. F. Bragança , Ivo

AU - Nielsen, Chris V.

AU - Alves, Luis M.

AU - Martins, Paulo A.F.

N1 - © 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).

PY - 2018

Y1 - 2018

N2 - A new joining by forming process that combines lancing and shearing with sheet-bulk compression is utilized to assemble thin-walled crash boxes utilized as energy absorbers. Process design and fabrication of the new crash boxes are analyzed by finite elements and experimentation. Axial crush tests were performed to compare the overall crashworthiness performance of the new crash boxes against that of conventional crash boxes assembled by resistance spot-welding. Results show that the joining process is a good alternative to resistance spot-welding because the new crash boxes can absorb the same crushing energy, and because the new process helps to overcome typical manufacturing problems of welding.

AB - A new joining by forming process that combines lancing and shearing with sheet-bulk compression is utilized to assemble thin-walled crash boxes utilized as energy absorbers. Process design and fabrication of the new crash boxes are analyzed by finite elements and experimentation. Axial crush tests were performed to compare the overall crashworthiness performance of the new crash boxes against that of conventional crash boxes assembled by resistance spot-welding. Results show that the joining process is a good alternative to resistance spot-welding because the new crash boxes can absorb the same crushing energy, and because the new process helps to overcome typical manufacturing problems of welding.

KW - Crash boxes

KW - Joining by forming

KW - Resistance spot-welding

KW - crashworthiness

U2 - 10.3390/ma11071118

DO - 10.3390/ma11071118

M3 - Journal article

C2 - 29966320

SN - 1996-1944

VL - 11

JO - Materials

JF - Materials

M1 - 1118

ER -

On the Performance of Thin-Walled Crash Boxes Joined by Forming

Abstract

Bibliographical note

Keywords

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