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Materials 2018, 11(7), 1118; https://doi.org/10.3390/ma11071118

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

1
Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
2
Instituto Superior de Engenharia de Lisboa, Rua Conselheiro Emídio Navarro, 1959-007 Lisboa, Portugal
3
Department of Mechanical Engineering, Technical University of Denmark, 2800 Kgs. Lyngby, Denmark
*
Author to whom correspondence should be addressed.
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))
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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. 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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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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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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