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On the Performance of Thin-Walled Crash Boxes Joined by Forming
Diogo F M Silva1, Carlos M A Silva2, Ivo M F Bragança3
1Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal. diogogjmsilva@tecnico.ulisboa.pt.
Materials (Basel, Switzerland)
|July 4, 2018
Summary
A novel joining process offers a superior alternative to resistance spot-welding for manufacturing energy-absorbing crash boxes. This method achieves comparable crashworthiness while mitigating common welding defects in automotive applications.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Thin-walled crash boxes are crucial energy absorbers in automotive safety.
- Conventional assembly methods like resistance spot-welding present manufacturing challenges.
Purpose of the Study:
- To introduce and analyze a new joining process for thin-walled crash boxes.
- To evaluate the crashworthiness of crash boxes produced by this new method.
- To compare the new process against traditional resistance spot-welding.
Main Methods:
- Utilized a novel joining process combining lancing, shearing, and sheet-bulk compression.
- Employed finite element analysis and experimental fabrication for process design.
- Conducted axial crush tests to assess crashworthiness performance.
Main Results:
- The new joining process is a viable alternative to resistance spot-welding.
- Crash boxes manufactured with the new process exhibit equivalent energy absorption capabilities.
- The novel method effectively addresses typical manufacturing issues associated with welding.
Conclusions:
- The lancing, shearing, and sheet-bulk compression joining technique is a promising advancement for energy absorber production.
- This innovative approach enhances manufacturing efficiency and product reliability in automotive safety components.
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