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Open AccessArticle

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

Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
Instituto Superior de Engenharia de Lisboa, Rua Conselheiro Emídio Navarro, 1959-007 Lisboa, Portugal
Department of Mechanical Engineering, Technical University of Denmark, 2800 Kgs. Lyngby, Denmark
Author to whom correspondence should be addressed.
Materials 2018, 11(7), 1118;
Received: 7 June 2018 / Revised: 26 June 2018 / Accepted: 28 June 2018 / Published: 29 June 2018
(This article belongs to the Special Issue Special Issue of the Manufacturing Engineering Society (MES))
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. View Full-Text
Keywords: crash boxes; joining by forming; resistance spot-welding; crashworthiness crash boxes; joining by forming; resistance spot-welding; crashworthiness
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MDPI and ACS Style

Silva, D.F.M.; Silva, C.M.A.; Bragança, I.M.F.; Nielsen, C.V.; Alves, L.M.; Martins, P.A.F. On the Performance of Thin-Walled Crash Boxes Joined by Forming. Materials 2018, 11, 1118.

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