Shape optimization of high-energy absorbers

In this paper, a new approach to simulate and to optimize the performances of a crash-box, in terms of energy absorption or acceleration peak, is presented. As soon as the maximum size of the crash-box (longitudinal and transversal dimensions) has been fixed, the new approach allows optimizing the shape of the transversal section and the thickness of the structure. Thanks to the proposed procedure, engineers can easily identify the best crash-box depending on the particular working conditions. The new method has been tested with different cases study by considering different objective functions. The obtained results show the procedure works well and also demonstrate that the optimal number of edges of the transversal section and the optimal crash-box thickness strongly depend on its main dimensions and on the considered objective function.