Multi-objective design of honeycomb hybrid crash box under frontal loading

This research aims to obtain the optimal honeycomb hybrid crash box design. Finite elements, parametric studies, and multi-objective optimization are carried out sequentially. Parametric studies are carried out to obtain important parameters to increase energy absorption and minimize mass. The effect of structure angle, honeycomb side length, and structure thickness are selected as the design parameter. Energy absorption and crash box mass are observed as design responses. Based on the results, it can be determined the optimal design from multi-objective optimization is angle structure of 21.1310, side length of 8.006 mm, and thickness of 1.2 mm. The model validation results for the optimal solution are appropriate; it is characterized by a honeycomb-filled structure that supports the folding of the outer wall of the crash box.