Effect of Adding a Trigger Hole and Cross-Section Foam on the Crash Box in Energy Absorption

Ahmad Yunus Nasution; Mohd Ruzaimi Mat Rejab; Januar Parlaungan Siregar

Effect of Adding a Trigger Hole and Cross-Section Foam on the Crash Box in Energy Absorption

Authors

Ahmad Yunus Nasution Mechanical Engineering Department, Engineering Faculty, Universitas Sumatera Utara, Jl. Dr. T. Mansur, 20155 Medan, Sumatera Utara, Indonesia; Faculty of Mechanical and Automotive Engineering Technology, University Malaysia Pahang Sultan Abdullah, 26600 Pekan, Pahang, Malaysia
Mohd Ruzaimi Mat Rejab Faculty of Mechanical and Automotive Engineering Technology, University Malaysia Pahang Sultan Abdullah, 26600 Pekan, Pahang, Malaysia
Januar Parlaungan Siregar Faculty of Mechanical and Automotive Engineering Technology, University Malaysia Pahang Sultan Abdullah, 26600 Pekan, Pahang, Malaysia

Keywords:

Crash box, frusta model, Trigger Circle

Abstract

Crash box, as passive safety components in passenger cars, continue to be modified to enhance their ability to protect drivers. This study modifies crash box using nine specimens: three square, three hexagonal, and three circular models, designed with SolidWorks. Testing was conducted using the Finite Element Method (Abaqus) and experimental compression tests with a Universal Testing Machine. The material used is Aluminum AA 6061-T4, with manufacturing processes including cutting, marking, bending, and TIG welding. Results show that the two-hole hexagonal crash box has the highest energy absorption: 33.05 kJ experimentally and 29.49 kJ in simulation, indicating significantly improved crashworthiness.

Published

2026-01-29

How to Cite

Nasution , A. Y., Mat Rejab, M. R., & Siregar, J. P. (2026). Effect of Adding a Trigger Hole and Cross-Section Foam on the Crash Box in Energy Absorption. Environment-Behaviour Proceedings Journal, 10(SI42). Retrieved from https://ebpj.e-iph.co.uk/index.php/EBProceedings/article/view/7750