Axial Crushing and Energy Absorption Integrated Design of Modular Filled Double-Hat Beam Composite Structures

In order to study the influence of modular filled and composite material forms on the axial crushing and energy absorption properties of structures, modular filled composite structures were constructed, and innovatively applied to the inner side of double-hat beam (DHB) structures in automobiles. The modular filled structures comprise hexagonal, quadrilateral, and triangular sections. By analyzing the collision performance of modular filled DHB structures, significant enhancements were observed in both the sectional characteristics and the specific Mean Crushing Force of modular filled DHBs compared to the conventional double-hat beam structure. These advancements notably improved the plastic deformation characteristics of the structures. Additionally, dynamic weightlessness experiments were conducted to validate the accuracy of the simulation model. Among the proposed schemes, namely QU-5, HE-5, and TR-5, notable improvements in crashworthiness were identified. Specifically, crashworthiness indicators increased by 32.54%, 78.9%, and 116.53%. Compared with other thin-walled structures, modular filled composite DHBs have advantages in axial crushing and energy absorption. By optimizing layout characteristics, the modular filled structures will achieve significant lightweight and energy absorption performance improvements. This work has clear reference value for automotive engineers and scholars to further explore the axial crash safety, platform modularization, and lightweight design of vehicles.