Materials, Vol. 11, Pages 1118: On the Performance of Thin-Walled Crash Boxes Joined by Forming Materials doi: 10.3390/ma11071118 Authors: Diogo F. M. Silva Carlos M. A. Silva Ivo M. F. Bragança Chris V. Nielsen Luis M. Alves Paulo A. F. Martins 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.
Mechanical Engineering, Materials Science, Production Engineering, Mining and Metallurgy, Traffic Engineering, Precision Mechanics